Facts Figures Book

$25.00

FACTS & FIGURES

Kolberg-Pioneer, Inc.

Johnson Crushers Intranational, Inc.

Astec Mobile Screens, Inc.

KPI-JCI and Astec Mobile Screens represents the only lines of Crushing, Screening, Material Handling, Washing, Classifying and Feeding equipment and systems designed, manufactured and supported in the U.S.A., and backed by authorized dealers worldwide. KPI-JCI and Astec Mobile Screens continues to lead the industry with tomorrow’s technology delivering the right equipment and systems today to meet your application and production needs of tomorrow. From concept to production, innovative products to world- class support, KPI-JCI and its distributors offer you the most experienced team in the industry ready to offer you simple and profitable solutions that meet all your objectives PROFITABILITY! KPI-JCI and Astec Mobile Screens is Your One Source supplier for all your aggregate, recycle and re-mediation needs.

FIFTH EDITION KPI-JCI and Astec Mobile Screens is a worldwide and industry leader for bulk material handling and processing equipment including; conveyors, screening plants, pugmill plants, sand and aggregate washing/classifying systems and all types of mobile, portable and stationary aggregate processing plants for the aggregate, recycle and construction industries. KPI-JCI and Astec Mobile Screens has made every effort to present the information contained in this booklet accurately. However, the information should be a general guide and KPI-JCI and Astec Mobile Screens does not represent the information information as exact under all conditions. Because of widely-varying field conditions and characteristics of material processed, information herein covering product capacities and gradations produced are estimated only. Products of KPI-JCI and Astec Mobile Screens are subject to the provisions of their standard warranty. All specifications are subject to change without notice.

© KPI-JCI 3.5M pg

08/14

Printed in U.S.A.

FORWARD Aggregate production is based on mathematical relationships, volumes, lengths, widths, heights and speeds. Because of widely-varying field conditions and characteristics of material processed, information herein relating to machine capacities and gradations produced are estimates only. Much of this data of special interest to producers and their employees has been included in this valuable booklet. We at KPI-JCI and Astec Mobile Screens hope you find this resource a valuable tool in your organization and operations. Count on us to be your supplier for all your aggregate, recycle and construction needs.

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1

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1 . O N E R U G I F

l ) t . e a s n e r r N a e e u l u c o a , i O n r I e v u m n T o m o a d s h n C t d s e e t a r U d o y b D e k n g f a O h r r o s e R E u o n s P U r e m w f c t r D L d e d o t L A n n e n a V v i R l , a i s e Y e e O n l u d v B o W a r c i w x d E r g e ( e l r b V d I o s n m T a u e w c A d n r L n e u o E a h t s R S e r

S G S U f o y s e t r u o C

0 9 9 1 , k c e h c s t a w a L r e t f a d e i f i d o M

3

4

5

6

TABLE OF CONTENTS Angle of Repose/Surcharge ................................................... 191 Autogenous Crushing .......................................................... 74, 81 Belt Speed ................................................................................. 196 Blade Mills ......................................................................... 105-106 Classifying Controls (Spec-Select I, II and III) .................................. 124-125 Introduction............................................................................ 107 Pipes, Velocity Flow and Friction Loss ................................... 120 Tanks .............................................................................. 119-123 Weir Flow ...................................................................... 123, 213 Coarse Material Washing ............................................... 100-106 Crushers Cones Kodiak Series ........................................................ 33, 34-56 LS Series............................................................... 33, 57-64 Horizontal Shaft Impactors (HSI) Andreas style ........................................................ 28, 31-32 New Holland style ................................................. 28, 29-30 Jaws ................................................................................... 22-27 Rolls ................................................................................... 65-72 Vertical Shaft Impact crushers (VSI) .................................. 73-81

Crusher notes Kodiak and LS Series ............................................................... 34 Vertical Shaft Impactor (VSI) ............................................. 74, 81

Data Angle of repose – surcharge .................................................. 191 Belt carrying capacity ............................................................. 188 Belt speeds.................................................................... 189, 193 Calculations...................................................................... 193 Elevation, conveyors ...................................................... 181-184 Horsepower requirements .............................................. 191-192 Idler classification ................................................................... 182 Incline, bulk materials, recommended .................................... 180 Stockpile Circular ............................................................................. 186 Conical ............................................................................. 185 Extendable stacker........................................................... 200 Volume ............................................................................. 187 Weights, common materials ........................................... 223-225 Weir flow........................................................................ 123, 213 Data, Industry Terms and Definitions ........................... 241-246 Dredge pump.......................................................................... 210 Electric motors and wiring .............................................. 205-209

4

Generator sizing ..................................................................... 209 Pipes, velocity flow and friction loss ............................... 211-212 Railroad ballast....................................................................... 203 Riprap ..................................................................................... 204 Spray nozzles ................................................................. 214-218 Weights and measurers ................................................. 219-225 Definitions and Terms ..................................................... 241-246 Fine Material Washing ..................................................... 107-112 FM (Fineness Modulus) ............................................................ 99

FRAP ........................................................................ 167-179 General Information on the Aggregate Industry ........... 3, 8-11 Gradations Aggregates ............................................................. 13-15, 94-95 ASTM C-33, C-144 ............................................................. 94-98 Hoppers ......................................................................................... 17 Horizontal Shaft Impactors (HSI) Andreas style............................................................... 28, 31-32 New Holland style........................................................ 28, 29-30 Material Handling............................................................. 180 Belt speeds............................................................ 188-189, 193 Recommended by material .............................................. 189 Calculations...................................................................... 187 Capacity, belt.......................................................................... 188 Elevation......................................................................... 183-184 Horsepower requirements .............................................. 191-192 Idler classification ................................................................... 182 Incline bulk materials, recommended ..................................... 180 Models, sizes and selections.......................................... 194-201 Pugmills ...................................................................................... 202 Screening and Washing Plants ..................................... 126-127 Screens, calculating area VSMA ........................................... 147 Screens, Types Horizontal ............................................. 143-144, 148, 159-162 Incline ............................................................ 141-142, 148-157 Multi-Slope (Combo) ..................................... 144-145, 163-165 High Frequency ................................................................132-139 Sieve sizes ......................................................................... 94-99 SE (Sand Equivalent test) ........................................................ 99 Sieve sizes .............................................................................. 12-13 Spray nozzles .................................................................... 214-217

Stockpile Angle of Repose/Surcharge ................................................... 191 Circular ................................................................................... 187 Conical ................................................................................... 185 Extendable Stacker ................................................................ 200

5

Volume ................................................................................... 187 Terms and Definitions ..................................................... 241-246

Track Mounted Plants Fast Trax ® Screen Plants ......................................................... 82 Fast Trax ® High Frequency Screen Plants ............................... 83 Fast Trax ® Jaw Plants .............................................................. 84 Fast Trax ® Kodiak Plus Cone Plants ........................................ 85 Fast Trax ® Impactor Plants....................................................... 86 Global Track Screening Plants ................................................. 87 Global Track Direct Feed Plants .............................................. 88 Global Track Jaw Plants........................................................... 89 Global Track Kodiak Plus Cone Plants .................................... 90 Global Track Conveyors ........................................................... 91

Typical Gradation Curve Gravel Deposit........................................................................... 14 Limestone Quarry Run .............................................................. 15 Washing Introduction ........................................................... 92-93 ASTM C-33, C-144 ............................................................. 96-98 Blade Mills ..................................................................... 105-106 Classifying ...................................................................... 107-125 Coarse material washing ............................................... 100-106 Controls .......................................................................... 124-125 Dredge pump.......................................................................... 210 Fine material washing .................................................... 107-112 Fineness Modulus (FM)......................................................... 101 Log Washers ................................................................. 101-102 Sand Equivalent test (SE) ........................................................ 99 Series 9000 Dewatering Screen.................................... 128-129 Series 9000 Plants ................................................................ 130 Screening and Washing plants....................................... 126-127 Weights and Measures.................................................... 218-240 World Production .......................................................................... 3

6

NOTES:

7

GENERAL INFORMATION ON THE INERT MINERAL (AGGREGATE) INDUSTRY Modern civilization is based on the use of inert minerals for concrete and asphaltic products. In truth, aggregate production is the largest single extractive industry in the United States. In excess of 2.8 billion tons of sand, gravel and crushed rock are produced annually. Because aggregates play such a vital role in the continuing growth of the nation and the world, demand for all types can be expected to increase substantially in the years ahead. There is great romance about these commonplace minerals; the earth sciences tell us a compelling story of the evolution of the earth’s mantle and its minerals which man has found so valuable to the civilizing processes on his planet. Since the earliest Ice Age, erosion of the continental rock by earth, wind, rain and fire has resulted in fractions being carried down the mountains by wind and water, the grains settling in an almost natural grading process. Other natural events such as floods and upheavals caused rivers and streams to change courses, burying river beds that have become high production sand and gravel operations in our time. Evaporation, condensation, precipitation and chemical actions, percolation and fusions have formed other rock materials that have become valuable aggregates in modern times. Advancements in geology and technology aid the industry in its progress to greater knowledge about these building blocks of all ages and civilizations. Locating these minerals has become much easier, too— and just in time, as recently the nation has acknowledged the state of neglect of hundreds of thousands of miles of state and county roads. The massive interstate program has dominated the expenditure of roadbuilding funds at the expense of these rural highways, so that today there are vast amounts of repair, reclamation and replacement of roads to be done. And, of course, locating nearby sources of roadbed materials wherever possible will affect the economy of construction, and in some cases, even the kind of construction as well.

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Rapid field investigations for possible sources of minerals have been made very simple and relatively inexpensive by the use of portable seismic instruments and earth resistivity meters. The latter are especially effective in locating sand, gravel and ground water by measuring the inherent electrical characteristics of each. Briefly, an alternating current is applied across electrodes implanted at known spacings in the surface soil; the potential drop of the current between the electrodes indicates whether the subsurface geology includes any high resistance areas, indicating sand, gravel or water. Another tool, the portable seismic instrument, is used to measure the velocity of energy transmitted into the earth as deep as 1,000 feet. The velocity of the energy wave’s travel through the subsurface geologic structure indicates the density or hardness of each layer or strata. For example, the velocity of topsoil may be 3,000 feet per second while limestone, granite and other potentially useful inert materials may have velocities beyond 12,000 feet per second. Thus, where the occurrence of aggregate material is not always convenient to the shortest haul routes or major population centers, locating and utilizing them have benefitted greatly by modern technology.

CLASSES OF AGGREGATES There are two main classes of aggregates. 1. Natural aggregates in which forces of nature have produced formations of sand and gravel deposits. These may include silts, clays or other foreign materials which are difficult to reject. Further, gradations may be quite different than those required for commercial sales. To meet such requirements, it becomes necessary to process or beneficiate natural aggregate deposits. 2. Manufactured aggregates are obtained from deposits or ledges of sedimentary rock (formed by sediments) or from masses of igneous rock (formed by volcanic action or intense heat). These are blasted, ripped or excavated and then crushed and ground to specified gradations. These deposits, too, may include undesirable materials such as shales, slates or bodies of metamorphic or igneous rock. Such deleterious materials must be removed in the processing operations. 9

PROCESSING OF AGGREGATES Much of the equipment used in the processing of raw aggregates has been adapted from other mineral processing techniques and modified to meet the specific requirements of the crushed stone, sand and gravel industry. Other types of equipment have been introduced to improve efficiency and final product. The equipment is classified in four groups. 1. Reduction equipment: Jaw, cone, roll, gyratory, impact crushers and mills; these reduce materials to required sizes or fractions. 2. Sizing equipment: Vibratory and grizzly screens to separate the fractions in varying sizes. 3. Dewatering equipment: Sand sorters, log washers, sand and aggregate preparation and fine and coarse recovery machines. 4. Sorting equipment. This can include various kinds of feeder traps and conveyor arrangements to transfer, stockpile or hold processed aggregates. As to method, there are two types of operations at most sand and gravel pits and quarry operations. They include: 1. Dry process: Here, the material is excavated by machines or blasted loose and is hauled to a processing plant without the use of water. 2. Wet process: This may involve pumping (dredge pumps) or excavation (draglines) of the aggregate material from a pit filled with water. The material enters the processing operation with varying quantities of water. The ideal gradation is seldom, if ever, met in naturally occurring sand or gravel. Yet the quality and control of these gradations is absolutely essential to the workability and durability of the end use. The aggregate has three principal functions: 1. To provide a relatively cheap filler for cementing or asphaltic materials. 2. To provide a mass of particles that will resist the action of applied loads, abrasion, percolation of moisture and water. 3. To keep to a minimum the volume changes resulting from the setting and hardening process and from moisture changes. 10

The influence of the aggregate on the resulting product depends on the following characteristics: 1. The mineral character of the aggregate as related to strength, elasticity and durability. 2. The surface characteristics of the particles, particularly as related to workability and bonding within a hardened mass. 3. Aggregate with rough surfaces or angular shapes does not place or flow as easily into the forms as smooth or rounded grains. 4. The gradation of the aggregates, particularly as related to the workability, density and economy of the mix. Of these characteristics, the first two are self-explanatory and inherent to a particular deposit. In some cases, an aggregate can be upgraded to an acceptable product by removing unsound or deleterious material, using benefication processes. Gradation, however, is a characteristic which can be changed or improved with simple processes and is the usual objective of aggregate preparation plants.

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SIEVE ANALYSIS ENVELOPE Percent passing by weight 100

80

60

40

s e v e i s 4 0 0 1 s o N

s e v i e s . i n 5 . 1 4 s o N

20

0 100

50

30

16

8

4

3 1 / / 8 2

3 / 4

1

11 / 2

Standard sizes of square-mesh sieves Curves indicate the limits specified in ASTM for fine and coarse aggregate

FIGURE NO. 2

EXAMPLE OF ALLOWABLE GRADATION ZONE IMPORTANCE OF GRADATION—CONCRETE To improve workability of concrete, either the amount of water or the amount of fine particles must be increased. Since the water-to-cement ratio is governed by the strength required in the final cured concrete, any increase in the amount of water would increase the amount of cement in the mix. Since cement costs are much greater than aggregate, it is evident that varying the gradation is more economical. Most of the formula used for proportioning the components of the concrete have been worked out as the results of actual experimentation. They are based, however, on two fundamentals. 1. To obtain a sound concrete, all voids must be filled either with fine aggregates or cement paste. 2. To obtain a sound concrete, the surface of each aggregate particle should be covered with cement paste. An ideal mix is a balance between saving on cement paste by using fine aggregates to fill the voids, and the added paste required to cover the surfaces of these additional aggregate particles.

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ACTUAL GRADATION The ideal gradation is seldom, if ever, met in naturallyoccurring sand or gravel. In practice, the quality of the gradation of the aggregate, the workability of the concrete, cement and asphalt requirements must be balanced to achieve strength and other qualities desired, at minimum total cost. Sizing of material larger than No. 8 sieve is best and most economically done by the use of mechanical screens of various types, either dry or wet. In actual practice, however, the division between coarse aggregates, which require different equipment for sizing, is set at No. 4 sieve (Fig. 3). Percent Weight Retained

Sieve No.

Allowable Cumulative

Sample Tested Individual

Cumulative

Min.

Max.

3 ⁄ 8”

0

0

0

0

4

0

10

4

4

8

10

35

11

15

16

30

55

27

42

30

55

75

28

70

50

80

90

18

88

100

92

98

8

96

Pan

100

100

4

100

FIGURE NO. 3

Tables have been published to facilitate these calculations, and they are based on the maximum size of the coarse aggregate which can be used for the specific type of construction planned.

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TYPICAL GRADATION CURVES FOR GRAVEL DEPOSITS SIEVE ANALYSIS inches 0 6 5 4

% RETAINED 20

40

60

80

mm 100 152 127 102

3

76.2

2 1-1/2 1-1/4 1

50.8 38.1 31.8 25.4

3/4

19.0

1/2

12.7

3/4

9.53

E 1/4 Z I #4 S E V #8 E I #10 S

6.35

#16 #20 #30 #40 #50 #60

KEY: 35/65 Heavy Gravel 50/50 Deposit 65/35 Heavy Sand

#80 #100 #200 100

80

60

40

% PASSING

14

20

0

TYPICAL GRADATION CURVES FOR LIMESTONE QUARRY RUN

15

APRON FEEDERS

Particularly suited for wet, sticky materials, the Apron Feeder provides positive feed action while reducing material slippage. Feeder construction includes heavy-duty and extra-heavy-duty designs, depending upon the application.

16

m 3 1 8 8 5 . 0 . 7 . . . . 7 1 1 2 — — m 5 6 6 2 1 1 1 . 4 t . 3 . 5 6 7 F 2 . 9 . 8 . . . . d 4 5 6 — — 4 7 7 8 Y 1 1 1 1 m 3 1 2 6 9 0 6 6 4 . . 8 . 4 . 8 . 5 . 9 . 5 . 0 6 m 4 6 1 . 3 t . 3 . 4 8 7 6 6 F . 0 . 6 . 3 . . . . . d 0 1 2 3 2 5 6 6 7 Y 1 1 1 1 1

g k g k g k g g k g k k 8 3 6 1 3 5 1 4 9 3 3 8 ) 1 4 7 1 r 9 9 1 1 1 2 e p t p h o g H i e . s . s . s . s . s . W h t s i b b b b b b W l l l l l ( l 0 5 0 5 0 0 5 6 5 7 5 1 0 5 1 7 2 1 2 2 3 9 3 4 s r e t 9 9 9 e 3 3 3 . . . 9 9 . . . y M t . 1 1 1 1 1 9 1 i c u a C p a C r e s p d p o r a 7 7 7 . 1 . 1 . 6 . 6 . 6 . H Y 1 2 2 2 . u C

S m 7 . 4 . 3 . 9 . 0 . 4 . 4 . 0 . 5 m 3 R 3 6 6 4 7 4 8 0 . E 3 D E t . . 3 3 8 0 3 7 8 5 E F . . 8 . 4 . 9 . 5 . 9 . 5 . 0 d F 0 4 Y 1 N 1 . q O S 3 3 3 4 4 4 s R 8 r . 8 . 8 . 1 . 1 . 1 . e m 4 4 8 8 0 2 4 6 e z P 1 1 1 2 2 2 t i e . 4 . 2 . 4 . 3 . 5 . 3 . 5 . S A 4 m 2 4 M . r S e 2 p — . R p q S o S E H t . 6 6 6 7 7 7 E t . d D I . 2 8 6 3 9 8 4 4 F F . . . . . . . . T 8 Y 3 5 3 6 3 6 4 7 E I E C F A E P m T ) ) 6 5 8 8 0 0 A ) ) ) ) h . . . . . . 3 h A / h h h h — — m / t 1 2 1 2 2 3 8 / / / / C 1 . t t t t t L m m m m m m E P * 1 ( 2 0 0 4 T 8 2 y 7 9 9 4 1 7 2 G i t A t . 3 3 5 2 c N M 6 5 5 2 a 1 3 4 6 6 9 7 6 I F M . . . . . . . d 3 9 9 7 p 3 I a P R 0 1 1 1 1 2 9 X 6 Y 2 3 2 3 2 3 — — T C A ( ( ( . 0 ( ( ( 6 O x C H H H H H t o H P P P P r R a P O P T T T T p T T P p R 0 0 0 0 0 A 0 0 3 3 0 P 0 P 0 3 4 4 6 3 I A 2 0 5 5 0 0 C . 0 5 1 1 0 l 5 1 R 0 E 2 2 3 a 1 i 1 E r R e P t a P m O y H r d D o n n t R n n o o i i y o o s s A i i n n k s s n n n n o o c i i e i D n o n o e t t s s t i i e e x x t t s s n n s N x x E E e e n n t t y y y E E p t A e e t t t x t x t t d d d t t u u f u u u e x x E E T r r r u u o o o c d a d a D d a D D m E o E h i a o h h h S e t t t t v h p r n n y n y y d t h t h t h t i i i i 3

3

3

3

3

3

i i i i W W W W W W W W r r r r e e e e r r r r e e e e d d d d e e e e d d d d h e e e e e e e e t e F e F e F e F F F F d i F n n n n W n n n n o o o o r r r r o o o o r r r r p p p p p p p p A A A A A ) ) ) ) A ) A ) A ) ) m m m m m m m m m m m m m m m m 7 7 9 9 2 2 4 4 6 6 1 1 6 7 6 7 1 9 1 9 0 1 0 1 2 1 2 1 ( ( ( ( ( ( ( ( ” ” ” ” ” ” ” ” 0 0 6 6 2 2 8 3 3 3 3 4 4 4 8 4

v v v e a a a y S a a a t t t T e e e m S S H S H H o r f

d e e f f o e p y 7 0 2 2 4 4 t m 1 6 6 1 1 6 r 0 m 6 7 7 9 9 1 f o e z s i i S . e n 4 i 2 0 3 0 3 6 3 6 3 2 4 g n a R r l e P P P P P P * : e b d R R R R R R E o m T 5 1 7 6 u 2 3 0 3 3 3 2 4 O M N N 17

H T D I W O T G N I D R O C C A S R E D E E F N O R P A F O S E I T I C A P A C R U O H R E P E T A M I X O R P P A

18

, d s n d a o , i v s s 0 6 2 8 n 2 8 4 r n 8 9 1 2 a o 3 4 6 f o 0 2 5 7 p T 4 6 8 1 1 1 1 r t e e a d e s e d e n i e f p e W h m t ” o f 2 o c 7 3 o l t 0 0 e 0 0 0 0 0 s v 2 8 d 2 8 5 0 6 d a r e c t Y 3 4 6 8 9 1 1 2 1 f d o u o e r t t a n r , i l n a e i e r b e t s 0 a s 0 0 0 0 0 a n 5 0 0 m h 0 5 0 5 0 o 0 2 f 3 4 6 7 9 T 1 1 o 8 . f s e o n d o i i o t r i t W c d a n ” f o 0 c g 6 3 ; n i n e t e 2 3 4 5 7 8 8 d s u v e 2 3 4 5 6 7 8 i d n e i f Y 2 3 4 5 6 7 8 g : r 8 e A . m r . d e n d n a p y u . h t t e e u l r e c d f e r n h n t a e i p o h , l s l s b e e 2 9 4 2 7 3 8 i d n v 9 8 8 8 7 7 6 . o 1 2 3 4 5 6 7 w n a r o r u T t r t o t o e p d n c d e e a a e d n f p f e 0 i i f 0 g 7 m o i n . a W , r t 2 e e d 5 ” t t a e 3 g e a 8 h . e r n d e = f 1 4 3 w i h s = r y i 4 4 7 7 0 2 o s 3 g r h e s f b t i 4 1 8 5 2 0 7 d e . o e 1 2 2 3 4 5 5 t s Y w d w c i d ; l a ) u y a f f i g . r g x t u e n s t c s e a i d y x l b e m p e e i f w t h l t n o h x e u s d s i t d m 7 2 4 9 2 6 8 ( e n ; e e 4 2 9 6 4 1 8 s 2 r o s c a e 2 n T 1 2 2 3 4 5 5 i n b . h o e 2 t e r w e r = o e a d t h i p t r . . s x d s n i H e W d o , r t d . w y ” y d e l . n : 2 p t e u e a n f i 4 3 e s c v u a e t s , n f 4 8 3 7 2 6 g d s 9 r e f Y h U 0 6 1 7 2 8 3 e d n t h . i . v o 1 1 2 2 3 3 4 d w r u r , ; Y s i n r t C o e w n e e r o d d e c e d i f e e e e t o i e e i e d n T f f f d e n f a , e o f n o f o r e c o d e s d h s e s e i a t t t l e d i o f f i r l n 8 2 6 0 4 8 2 c d f a a f a o 0 7 2 7 3 h n o o a y T 1 6 1 1 2 2 3 3 4 p c a h l o h i t t c l i t a b d p i r e e u a e e h c d w d t t u i a q i = = g e m n W n l y i d w f t t a ” o i a i r c l 6 e e a u 3 3 p c t a p l a y 0 0 0 0 0 0 s a t 0 m 2 6 0 4 8 2 c d e c f e t Y 8 1 1 2 2 2 3 n h o t a e h h h t t i i m w p x e o d d w r e y r p a r e p a t n a v n o l e u i d h o s t e w c 2 8 6 3 0 6 n s 4 , e n 1 4 8 2 6 9 t a o 7 1 1 1 2 2 2 e b o a l o T e t u s b i r , l c e s e a o d y t v c i a o c a o b w t W l a f a s d ” i e l e l 0 i b h s T 3 3 a w . u t c 0 8 5 3 0 e s e 5 3 e t c b 1 3 6 9 2 d e h 5 8 n 1 1 1 1 2 i , n Y T a a . w r c g o a l n f l a v i u e d o l t a b m o e r l a ) . r c o f f l e n o n d a e i g i t h v s n t s i i a M n p s r w o e 0 5 0 5 0 5 0 r e o T e 1 1 2 2 3 3 4 C d r l : p n o E f a t . T e P O F h ( N T

e d i W m 3 8 . 1

e d i W m 2 5 . 1

e d i W m 2 2 . 1

e d i W m 7 0 . 1

e d i W m 4 1 9 .

e d i W m 2 6 7 .

6 t 2 8 4 8 7 2 7 8 6 8 8 0 1 3 5 m 9 3 5 7 9 1 1 1

5 6 7 9 1 4 6 8 8 1 3 5 7 m 4 2 3 4 6 7 8 9

3

9 t 2 4 0 6 3 8 7 8 0 4 8 1 5 m 2 4 5 6 8 9 0 1

0 4 0 4 9 7 4 5 9 3 7 m 1 2 3 2 4 1 5 9 5 6

3

t 4 8 3 7 3 0 7 7 2 6 m 1 2 4 3 4 2 5 1 6 9 6

9 4 7 3 2 3 7 7 6 2 m 0 1 6 1 1 2 2 3 8 3 4

3

t 3 1 6 7 5 1 8 3 m 3 1 0 2 2 3 3 0 4 6 4 3 5

5 6 7 9 0 2 3 0 5 9 8 2 m 3 1 1 2 2 2 3 3

3

t 8 4 7 6 4 5 3 3 2 9 4 m 9 1 9 1 2 2 3 9 3

2 3 3 4 5 5 8 1 4 6 2 9 2 m 1 1 1 1 2 2

3

t 7 2 4 9 2 6 9 3 6 0 3 m 6 0 1 1 1 2 2 6 2

5 6 7 8 2 4 4 3 6 4 8 0 m 2 1 1 1 6 1

3

r l e e p ) v e t 7 9 a 5 7 0 2 4 s r u 6 r 0 5 1 6 1 . 1 . T e n . . . . . i 0 2 t 3 4 6 7 9 n 1 1 e ( m a m P (

VIBRATING FEEDERS

Designed to convey material while separating fines, Vibrating Feeders provide smooth, controlled feed rates to maximize capacity. Grizzly bars are tapered to selfrelieve with adjustable spacing for bypass sizing. Feeder construction includes heavy-duty deck plate with optional AR plate liners. Heavy-duty spring suspension withstands loading impact and assists vibration.

SCALPING SCREEN SIZING FORMULA Scalping Area =

Tons / hour of undersize in the feed Capacity per square feet (“C”) x modifying factors “O” and “F”

CAPACITY FACTOR “C” SIZE OF OPENING (IN.)

FACTOR “C” PERFORATED PLATE GRIZZLY BARS

2 3 4 5 6 7 8 9 10

4.1 5.4 6.7 8.6 9.8 10.9 11.6 12.5 13.5

MODIFYING FACTOR “O” FOR PERCENT OF OVERSIZE IN THE FEED % 10 20 30 40 50 60 70 80 85 90

FACTOR 1.05 1.01 .98 .95 .90 .86 .80 .70 .64 .55

6.1 8.1 10.0 15.0 17.2 19.1 23.2 25.0 27.0 MODIFYING FACTOR “F” FOR PERCENT PASSING HOLES HALF-SIZE OF OPENING % 10 20 30 40 50 60 70 80 85 90

FACTOR .55 .70 .80 1.00 1.20 1.40 1.80 2.20 2.50 3.00

19

VIBRATING FEEDERS—APPROXIMATE CAPACITY* 30” (.76m) WIDE RPM 600 650 700 750 800 850 900 950 1000

TPH

270 290 305 325 345 365

36” (.91m) WIDE

mt/h

246 264 278 296 314 332

TPH

315 337 360 382 404 427

mt/h

287 307 328 348 368 389

42” (1.07m) WIDE

50” 1.27m) WIDE

60” (1.5m) WIDE

TPH

TPH

TPH

mt/h

828 898 967 1035

754 818 881 943

473 507 541 575 609 642

mt/h

623 671 720 767

431 462 493 524 555 585

mt/h 568 611 656 698

CAPACITY MULTIPLIERS FOR VARIOUS FEEDER PAN MOUNTING ANGLES FROM 0° TO 10° DOWN HILL— ALL VIBRATING FEEDERS Angle Down Hill

0°

2°

4°

6°

8°

10°

Multiplier

1.0

1.15

1.35

1.6

1.9

2.25

NOTE: *Capacity can vary ±25% for average quarry installations—capacity will usually be greater for dry or clean gravel. Capacity will be affected by the methods of loading, characteristics and gradation of material handled, and other factors.

(4° and more consult with Factory)

STANDARD HOPPER APPROXIMATE CAPACITIES VIBRATING FEEDERS Standard Feeder Size 30” x 12’ 30” x 12’ 36” x 14’ 36” x 14’ 36” x 16’ 36” x 16’ 42” x 15’ 42” x 15’ 42” x 17’ 42” x 17’ 42” x 18’ 42” x 18’ 42” x 20’ 42” x 20’ 50” x 16’ 50” x 16’ 50” x 18’ 50” x 18’ 50” x 20’ 50” x 20’ 60” x 24’ 60” x 24’

20

( 762mm x 3.7m) ( 762mm x 3.7m) ( 914mm x 4.3m) ( 914mm x 4.3m) ( 914mm x 4.9m) ( 914mm x 4.9m) (1067mm x 4.6m) (1067mm x 4.6m) (1067mm x 5.2m) (1067mm x 5.2m) (1067mm x 5.5m) (1067mm x 5.5m) (1067mm x 6.2m) (1067mm x 6.2m) (1270mm x 4.9m) (1270mm x 4.9m) (1270mm x 5.5m) (1270mm x 5.5m) (1270mm x 6.1m) (1270mm x 6.1m) (1524mm x 7.3m) (1524mm x 7.3m)

Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension Without Extension With Extension

Yds.3

M3

5.5 7.2 7.2 12.6 8.2 14.4 9.0 18.0 10.2 20.4 10.0 21.6 12.0 24.0 11.0 21.6 12.6 24.3 14.0 27.0 19.6 43.0

4.2 5.5 5.5 9.6 6.3 11.0 6.9 13.8 7.8 15.6 8.2 16.5 9.2 18.4 8.4 16.5 9.6 18.6 10.7 20.6 15.0 32.9

C

BELT FEEDER CAPACITY (TPH)

H (inches) R E D ) E ” E F 8 1 T = L E B W ( ” 4 2

R E D ) E ” E 4 F 2 T = L E B W ( ” 0 3

R E D ) E ” E F 0 3 T = L E B W ( ” 6 3

R E D ) E ” E F 6 3 T = L E B W ( ” 2 4

8

10 30

20 60

9

34

10

Belt Speed FPM

R U S H I N G

30 90

40 120

50 150

60 180

68

101

135

169

203

38

75

113

150

188

225

11

41

83

124

168

206

248

12

45

90

135

180

225

270

13

49

98

146

195

244

293

14

53

105

158

210

262

315

8

40

80

120

160

200

240

9

45

90

135

180

225

270

10

50

100

150

200

250

300

11

55

110

165

220

275

330

12

60

120

180

240

300

360

13

65

130

195

260

325

390

14

70

140

210

280

350

420

8

50

100

150

200

250

300

9

56

113

169

225

281

338

10

62

125

187

250

312

375

11

69

137

206

275

344

412

12

75

150

225

300

375

450

13

81

162

244

325

406

487

14

87

175

262

350

437

525

8

60

120

180

240

300

360

9

68

135

203

270

338

405

10

75

150

225

300

375

450

11

83

165

248

330

413

495

12

90

180

270

360

450

540

13

98

195

293

390

488

585

14

105

210

315

420

525

630

NOTE: Capacities based on 100 lb./cu. ft. material TPH = 3 x H (in.) x W (in.) x FPM 144

21

C

JAW CRUSHING PLANTS

R U S H I N G

Wheel-Mounted

Track-Mounted

Stationary 22

C

LEGENDARY JAW CRUSHER

R U S H I N G

For almost a century, Legendary Jaw Crushers have been processing materials without objection. Used most commonly as a primary crusher — but also as a secondary in some applications — these compression crushers are designed to accept all manner of materials including hard rock, gravels and recycle pavements, as well as construction and demolition debris.

23

C R U S H I N G

JAW CRUSHERS APPROXIMATE JAW CRUSHERS GRADATION OPEN CIRCUIT APPROXIMATE GRADATIONS AT PEAK TO PEAK CLOSED SIDE SETTINGS

Test 3

1 1 ⁄ 4”

1 1 ⁄ 2”

1 2 ⁄ 2”

Sieve

⁄ 4”

1”

Sizes

19

25.4

31.8 38.1 50.8

(in.)

mm

mm

mm

mm

2”

mm

1 3 ⁄ 2”

3”

4”

5”

6”

7”

8”

63.5 76.2 89.1

102

127

152

178

203 Sizes

mm

mm

mm

mm

mm

mm

mm

mm

12”

(mm)

98

95

305

100

97

95

90

254

100

96

92

85

75

203

100

97

92

85

76

65

178

100

98

93

85

74

65

53

152

100

97

95

85

73

62

52

40

127

100

96

90

85

70

56

45

38

28

102

100

93

85

75

65

50

38

32

27

23

76.2

100

95

85

73

62

52

38

31

24

22

17

63.5

100

96

85

70

55

47

39

28

24

20

17

13

50.8

8” Values Are Percent Passing

6” 5” 4” 3” 1 2 ⁄ 2”

2”

Sieve

100

10”

7”

Test

1 1 ⁄ 2”

100

93

85

67

49

39

33

27

21

18

15

13

10

38.1

1 1 ⁄ 4”

96

85

73

55

39

31

27

23

17

15

13

10

8

31.8

1”

85

69

55

40

29

24

20

17

14

12

10

8

6

25.4

⁄ 4”

3

66

49

39

28

21

18

15

13

11

9

8

6

5

19.0

⁄ 2”

1

41

29

24

19

14

12

10

9

7

6

6

5

4

12.7

⁄ 8”

3

28

21

18

14

11

9

8

7

5

5

5

4

3

9.53

⁄ 4”

1

18

14

12

10

7

7

6

5

4

4

4

3

2

6.35

#4

12

10

9

7

5

5

4

4

3

3

3

2

1

#4

#8

6

6

5

5

4

4

3

3

2

2

2

1

0.5

#8

The chart on this page is particularly useful in determining the percentages of various sized particles to be obtained when two or more crushers are used in the same setup. It is also helpful in determining necessary screening facilities for making size separations. Here is an example designed to help show you how to use the percentage charts: To determine the amount of material passing 1¼” (31.8 mm) when the crusher is set at 2” (50.8 mm) closed side setting: find 2” (50.8 mm) at the top, and follow down the vertical line to 1¼” (31.8 mm). The horizontal line shows 39% passing…or 61% retained.

24

C

5 7 8

” 4 m 2 0 1 3 m

H ” 9 2 m P 1 7 5 7 T 1 2 m N I ” 4 m 8 0 5 8 S 1 2 6 m E I T 8 m I 5 ” 2 9 2 C 2 m 6 A P * ” 3 m 0 2 2 2 A ) 0 9 2 2 8 H C P 2 m 6 5 5 6 5 T E N T 3 3 7 0 5 6 5 0 ( ” 8 m A I 7 7 3 5 1 6 0 7 S 1 2 4 3 6 4 4 5 m M G I I X N 2 9 8 3 0 7 0 7 8 ” T O T 5 m 3 7 1 3 3 0 6 1 E 2 3 3 5 4 4 4 m R S P E D P 7 m 7 0 5 8 2 3 8 0 0 0 6 2 8 4 8 2 6 5 5 5 7 S ” A I 5 1 m 1 2 2 2 3 2 4 3 3 3 D D E S N 2 6 4 3 6 1 7 3 5 8 3 0 2 2 4 ” m A O L 0 3 0 2 5 7 0 6 2 7 0 0 4 1 2 1 1 1 2 2 2 2 3 3 3 2 3 C 1 m D A E K 9 3 9 3 6 1 1 0 0 5 5 R 2 9 m 2 8 P ” ⁄ 0 6 3 5 8 1 4 0 3 7 7 I E 1 8 7 9 1 1 1 1 1 2 2 2 3 2 2 m 3 O U T . Q K % . E A 5 y 2 4 6 5 8 3 0 ” 6 m 3 5 6 2 E 4 2 3 6 8 1 9 r 6 9 1 8 1 1 1 1 2 2 R P 3 7 m ± o t s c T a a R F h E A t c ” l 2 9 3 5 5 S 2 4 m 8 4 7 9 4 1 4 u ⁄ u 2 4 6 1 6 2 4 6 8 5 8 2 7 0 m s I W E 1 1 1 1 1 m 2 n T s o I O a c C y P r A … . a 2 e E P ” 1 m 1 4 6 5 3 5 8 t v s a l 2 5 m 2 3 5 7 4 6 0 l S A y 1 6 e p C a d R E e m o l g y O T t g m i ” A n 2 8 m 9 9 4 9 6 4 1 o c ⁄ 3 1 2 4 5 3 5 8 H M t i 1 o a m t I 1 p d r c a X a u — C O d d . S R n o d ” r a r t 2 m 4 2 3 4 ⁄ P p a R 1 3 s 1 2 3 4 y m d 1 E P n c a r A i a b h H d t u n r c S ” 5 m 2 8 7 6 a t e r s h e U 1 2 m 1 1 2 3 t r p o e . R h s t g n b i C l o l w 0 ” 9 m 0 5 2 9 o d 0 ⁄ 4 1 m 1 1 2 2 e W n 3 7 , n e 2 i A r a t a g J b n o t i a 4

0 0 0 0 5 5 0 0 0 0 5 2 5 h M 0 e h t Y 9 9 9 9 7 7 6 6 6 6 3 g b P 9 i 2 2 2 2 2 2 2 2 2 2 2 2 2 s e R y e R w a z i l l s m A a i e r ) s 0 0 5 0 0 0 0 0 0 0 0 0 0 w 5 0 0 0 0 e D d m s g a 1 1 7 4 5 7 9 5 9 5 5 5 1 t j e 2 4 6 6 9 n a i e 1 1 1 1 1 1 1 2 1 2 2 2 3 i y r u D N P i t r m t e a m n i s E H u d t q o n r n 5 0 0 0 5 0 0 0 0 0 0 0 e i c e e 5 5 0 0 5 G R d e 2 0 0 2 5 0 5 0 0 0 5 g g e l 1 2 4 4 7 6 M r e 1 1 1 1 1 2 1 2 2 2 2 s ( E E a L a L B L 6 4 6 7 4 6 4 0 6 6 8 9 4 2 3 0 6 8 : E 1 2 3 4 2 3 5 3 3 3 4 4 5 4 6 5 4 4 E Z 0 5 1 5 6 5 2 I 1 0 1 0 1 0 1 1 1 8 1 0 2 4 2 1 2 6 2 8 2 0 3 1 3 3 3 3 4 T O S N *

* * * * *

* * *

* * *

* * *

* * *

* *

* * *

* *

* *

* *

* *

25

R U S H I N G

C

VANGUARD JAW CRUSHER

R U S H I N G

Today’s hard rock producer requires more out of a jaw crusher. The producer requires massive crushing energy and hydraulic closed-side-setting adjustment to increase productivity and reduce downtime. Used most commonly as a primary crusher — but also as a secondary in some applications — these compression crushers are designed to accept all manner of materials including hard rock, gravels and recycle pavements, as well as construction and demolition debris.

26

Vanguard Plus Jaw Crusher Animation http://youtu.be/DIwR7BZAnpg

C

” 4 m 2 0 1 3 m

R U S H I N G

” 9 m 1 7 1 2 m ” 4 m 0 5 1 2 m 8 m ” 9 2 2 m * ” ) 8 H P T H N P ( ” T I S 7 N I G N I T S ” T E 6 E I S T I E C D I ” A S 5 D S P A E R C O E E S ” L H T C 4 S A K A U M E I 2 R P ” ⁄ 1 X 3 C O O T R K W P A ” A E P 3 J A P T D D A ” 2 ⁄ R N S 1 E A I 2 A T I C U D E A G R P ” I A N U C 2 A Q E T ” V E 2 ⁄ R A 1 M I R X 1 E O ” 4 W R ⁄ P 1 P O 1 P A

E S R O H

0 5 2 7 0 7 1

3 m 0 2 m

7 5 5 6 6 8

8 m 7 1 m 2 5 m 1 m 7 m 2 1 m

8 9 9 1 6 9

2 0 0 6 5 6

5 3 0 3 4 5

0 4 8 6 5 7

5 1 2 9 5 6

1 8 2 1 6 8

7 9 4 8 4 5

4 6 5 6 3 4

4 3 0 6 5 6

0 5 6 0 4 6

5 8 4 1 5 7

8 0 2 0 2 3

8 3 6 5 2 3

2 3 8 0 3 5

4 0 0 0 3 4

6 4 3 7 4 5

5 0 9 2 3 5

7 5 6 1 4 6

0 0 9 5 1 2

3 4 2 9 2 2

7 8 1 1 3 4

4 4 5 3 2 3

3 5 5 6 3 4

2 0 4 5 3 4

2 9 0 2 4 5

9 8 m m

1 5 7 2 1 2

0 4 0 6 2 2

5 5 8 7 2 3

8 0 2 0 2 3

0 1 9 8 2 3

2 8 0 9 3 3

6 7 m m

0 0 5 0 1 2

9 5 7 3 1 2

2 1 5 3 2 3

1 5 0 6 2 2

2 1 5 3 2 3

3 5 3 7 1 1

7 6 5 0 1 2

2 m 0 1 m

4 m 6 m 1 5 m m 8 3 m m 2 3 m m

” 5 m 1 2 m ” ⁄ 4 9 1 m 3 m M P R l ) e s d e m i e u r D P i m u i H q n t e i c e R M ( l E E Z I S

5 0 0 0 0 5 2 5 8 6 5 6 5 2 2 2 2 2 2 2 2 0 0 0 0 0 0 0 6 9 5 9 5 5 1 1 2 1 2 2 1 3 5 2 1 0 4 6 2

0 5 1 0 5 6 2

0 0 2 5 5 0 3

0 5 1 4 4 1 3

0 0 2 5 6 1 3 * *

0 0 2 2 5 3 3 * *

0 5 2 0 5 4 4

. s c i t s i r e t c a r a h c l . a i y r r e o t a t c a m F e l t h t u s h t i n c w o y … r e a t v l a y a p e m l y g t g i o c t a d p r a a C d . n d a r t a y s c n a i h b t u r c e r h t e p o . h s t b l i w 0 d 0 e 7 n , 2 i a t g b n o i h e g b i e y w a l m a i s r g e t n a i t m t e s n o r e d g e r s a a L B * * * : E T O N 27

C

HSI PLANTS

R U S H I N G

Track-Mounted Andreas-Style

Wheel-Mounted Andreas-Style

Wheel-Mounted New Holland-Style 28

C

PRIMARY IMPACT CRUSHERS (New Holland Style)

R U S H I N G

Making a cubical product necessary for asphalt and concrete specifications poses many equipment problems for the aggregate producer. Among these problems are abrasive wear, accessibility for hammer maintenance or breaker bar changes and bridging in the crushing chamber. Impact crusher units are designed to help overcome problems faced by producers and at the same time to provide maximum productivity for existing conditions.

29

C R U S H I N G

PRIMARY IMPACT CRUSHERS (NEW HOLLAND STYLE)—APPROXIMATE PRODUCT GRADATION—OPEN CIRCUIT Test Sieve Sizes (in.)

3850 Normal Setting

4654

Close Normal Setting Setting

6064

Close Normal Setting Setting

Values are percent passing

6” 5”

100

100

4”

100

3”

96

1 2” 2 ⁄

Close Setting

Test Sieve Sizes (mm) 152

97

100

127

98

100

90

98

102

100

89

96

75

89

76.2

90

97

80

90

66

80

63.5

2”

77

89

67

77

56

67

50.8

1 2” 1 ⁄

64

75

56

64

48

56

38.1

1 4” 1 ⁄

57

67

50

57

43

50

31.8

1”

50

58

44

50

38

44

25.4

3 4” ⁄ 1 2” ⁄ 3 8” ⁄ 1 4” ⁄

41

47

37

41

31

37

19.1

32

37

28

32

24

28

12.7

26

30

23

26

19

23

9.53

20

23

17

20

14

17

6.35

#4

17

19

15

17

12

15

#4

#8

12

14

10

12

8

10

#8

#16

8

9

6

8

5

6

#16

#30

5

6

4

5

3

4

#30

#50

3

4

3

3

2

3

#50

#100

2

3

2

2

1

2

#100

Recommended HP

Approx. Capacities* mt/h

Maximum Feed Size

250-450

227-409

24”

400-750

364-682

30”

600-900 600-1200 545-1091

40”

Size

Electric

Diesel

3850

250-300

350-450

4654

300-400

450-600

6064

400-600

TPH

NOTE: *Capacity depends on feed size and gradation, type of material, etc. Approximate product gradation can be expected as shown on chart. The product will vary from that shown depending on the size and type of feed, adjustment of lower breaker bar, etc.

30

C

ANDREAS-STYLE IMPACT CRUSHERS

R U S H I N G

These impact crushers are designed for recycling concrete and asphalt, as well as traditional aggregate crushing applications. The Maximum Performance Rotor (MPR) offers the mass of a solid design with the clearances of an open configuration.

Andreas-Style HSI Animation http://youtu.be/1En-mdIjork

31

C

ANDREAS IMPACT CRUSHERS HORIZONTAL SHAFT IMPACT CRUSHER

R U S H I N G

Recommended HP

Approx. Capacities*

Size

Electric

Diesel

TPH

mt/h

4233

100

165

up to 200

up to 181

4240

150

190

up to 250

up to 227

4250

200

265

up to 300

up to 272

5260 - 3 bar

300

390

up to 450

up to 408

5260 - 4 bar

300

390

up to 450

up to 408

Size

Recycle

Limestone

Min Lower/ Upper Apron Setting Hard Rock

4233

24”x24”x12”

up to 18”

up to 16”

1” / 2”

4240

27”x27”x12”

up to 21”

up to 18”

1” / 2”

4250

30”x30”x12”

up to 21”

up to 21”

1” / 2”

5260 - 3 bar 36”x36”x12”

up to 24”

up to 21”

1” / 2”

5260 - 4 bar 36”x36”x12”

up to 21”

up to 18”

1” / 2”

Maximum Feed Size**

Approximate Output Gradations-Open Circuit 100% 90%

APRONS: Upper @ 4" Lower @ 2"

80%

g n 70% i s s a P60% e v 50% i t a l u 40% m u C30% %

8000 fpm

FEED

6500 fpm 5250 fpm

20% 10% 0% 50 mesh

8 mesh

1"

3"

10"12"

NOTE: *Capacity depends on feed size and gradation, type of material, etc. ** Limestone and hard rock feed sizes are based on secondary applications.

32

C

CONE CRUSHERS

R U S H I N G

Track-Mounted Kodiak Plus

Wheel-Mounted Kodiak Plus

Wheel-Mounted LS 33

C

KODIAK™ PLUS AND LS CONE CRUSHER NOTES R U S 1. Capacities and product gradations produced by cone H crushers will be affected by the method of feedI N ing, characteristics of the material fed, speed of the G machine, power applied, and other factors. Hardness, compressive strength, mineral content, grain structure, plasticity, size and shape of feed particles, moisture content, and other characteristics of the material also affect production capacities and gradations. 2. Gradations and capacities shown are based on a typical well-graded choke feed to the crusher. Well-graded feed is considered to be 90%-100% passing the closed side feed opening, 40%-60% passing the midpoint of the crushing chamber on the closed side (average of the closed side feed opening and closed side setting), and 0-10% passing the closed side setting. Choke feed is considered to be material located 360 degrees around the crushing head and approximately 6” above the mantle nut. 3. Maximum feed size is the average of the open side feed opening and closed side feed opening. 4. A general rule of thumb for applying cone crushers is the reduction ratio. A crusher with coarse style liners would typically have a 6 to 1 reduction ratio. Thus, with 3 a ⁄ 4” closed side setting, the maximum feed would be 3 4 or 4.5 inches. Reduction ratios of 8 to 1 may be 6 x ⁄ possible in certain coarse crushing applications. Fine liner configurations typically have reduction ratios of 4:1 to 6:1. 5. Minimum closed side setting may be greater than published settings since it is not a fixed dimension. It will vary depending on crushing conditions, the compressive strength of the material being crushed, and stage of reduction. The actual minimum closed side setting is that setting just before the bowl assembly lifts minutely against the factory recommended pressurized hydraulic relief system. Operating the crusher at above the factory recommended relief pressure will void the warranty, as will operating the crusher in a relief mode (bowl float). 34

C

KODIAK PLUS AND LS CONE CRUSHERS

R U S H I N G

KODIAK 300 PLUS CONE

KODIAK 500 PLUS CONE

1400 LS Cone

Kodiak Plus Cone Crusher Animation http://youtu.be/DEg97HrBzeE

35

C

KODIAK™ OPERATING PARAMETERS R U S The following list outlines successful operating paramH I N eters for the Kodiak Plus line of crushers. These are not G prioritized in any order of importance. Material

1. 2. 3. 4. 5. 6.

Material with a compressive strength greater than 40,000 pounds per square inch should be reviewed and approved in advance by the factory. No more than 10% of the total volume of feed material is sized less than the crusher closed side setting. The crusher feed material conforms to the recommended feed size on at least two sides. Moisture content of material below 5%. Feed gradation remains uniform. Clay or plastic material in crusher feed is limited to prevent the formation of compacted material or “pancakes” being created.

Mechanical

1.

Crusher operates at factory recommended tramp iron relief pressures without bowl float. 2. Crusher support structure is level and evenly supported across all four corners. In addition, the support structure provides adequate strength to resist static and dynamic loads. 3. Crusher is operated only when all electrical, lubrication and hydraulic systems are correctly adjusted and functioning properly. 4. Lubrication low flow warning system functions correctly. 5. Lubrication oil filter functions properly and shows adequate filtering capacity on its indicator. 6. Crusher drive belts are in good condition and tensioned to factory specifications. 7. Crusher lubrication reservoir is full of lubricant that meets factory required specifications. 8. Any welding on the crusher or support structure is grounded directly at the weld location. 9. Crusher input shaft rotates in the correct direction. 10. Manganese wear liners are replaced at the end of their expected life and before coming loose or developing cracks. 36

C

11. Crusher cone head is properly blocked prior to trans- R U port. 12. Only authorized OEM parts or factory-approved wear S H I parts are used. N G Application 1. Reduction ratio limited to 6 to 1 below 1” closed side setting and 8 to 1 above 1” closed side setting provided no bowl float occurs. 2. Manganese chamber configuration conforms to the factory recommended application guidelines. 3. Crusher is operated at the factory recommended RPM for the application. 4. Crusher feed is consistent, providing an even flow of material, centered in the feed opening, and covering the mantle nut at all times. 5. Crusher input horsepower does not exceed factory specifications. 6. Crusher discharge chamber is kept clear of material buildup. 7. If the crusher cannot be totally isolated from metal in the feed material, a magnet should be used over the crusher feed belt. 8. Crusher is never operated at zero closed side setting.

37

C

KODIAK 200 PLUS CONE CRUSHER GRADATION CHART

R U S H I N G

Crusher Closed Side Setting 5

3 7 1 ⁄ ⁄ ⁄ 2” 16” ⁄ 8” 16” Product

Size

7.94 mm

5

⁄ 8”

3

⁄ 4”

7

⁄ 8”

1”

9.52 11.11 12.7 15.87 19.05 22.22 25.4 mm mm mm mm mm mm mm

11 ⁄ 4” 11 ⁄ 2” 13 ⁄ 4” 32 mm

38.1 44.5 mm mm

4”

2” 50.8 mm 100

1 3 ⁄ 2”

100

96

3”

100

95

90

23 ⁄ 4”

98

92

86

1 2 ⁄ 2”

100

95

88

81

1 2 ⁄ 4”

97

91

83

74

100

94

86

76

65

100

97

88

79

66

55

100

95

91

80

68

56

45

100

97

90

83

70

56

46

38

100

99

90

82

72

58

45

36

29

100

99

93

86

74

64

48

38

30

25

2” 13 ⁄ 4” 1 1 ⁄ 2” 1 1 ⁄ 4”

1” 7 8” ⁄ 3 4” ⁄

100

97

94

87

80

65

54

40

32

26

21

5 8” ⁄

98

94

87

80

69

55

46

34

28

22

18

1 2” ⁄

100

95

88

80

69

58

47

39

28

23

19

16

3 8” ⁄

91

84

73

63

52

44

37

28

21

17

14

12

⁄ 16”

85

74

63

54

46

37

31

25

19

15

13

10

1 4” ⁄

74

61

50

44

36

32

26

21

16

13

11

9

4M

58

48

42

35

32

26

21

18

14

11

9

7

5

⁄ 32”

50

41

36

30

28

23

18

15

12

10

8

6

8M

40

35

30

26

24

20

16

12

9

7

5

4

10M

35

31

26

22

20

18

14

10

8

6

4

3

16M

28

24

21

17

15

13

10

8

6

4

3

2

30M

20

18

15

11

9

8

6

5

4

3

2

1.5

40M

18

15

14

10

8

7

5

4

3

2

1.5

1

50M

14

12

12

8

7

6

4

3

2

1.5

1

0.8

100M

11

9

9

7

6

5

4

3

1.5

1

0.5

0.5

200M

8

7

6

6

5

4

3

2

1

0.5

0.5

0.3

5

Estimated product gradation percentages at setting shown.

38

C

KODIAK 200 PLUS MANGANESE CONFIGURATION

R U S H I N G

Kodiak 200 Plus Coarse Chamber

Mantle: 406051X Bowl Liner: 406053X All Dimensions in Inches A B C 10 (254mm) 9 (228.6mm) 2 (50.8mm) 1 1 1 9 ⁄ 8 ⁄ 1 ⁄ 2 (241.3mm) 2 (215.9mm) 2 (38.1mm) 1 1 1 4 (234.9mm) 4 (209.5mm) 4 (31.7mm) 9 ⁄ 8 ⁄ 1 ⁄ 9 (228.6mm) 8 (203.2mm) 1 (25.4mm) 7 ⁄ 8 (22.2mm) 83 ⁄ 4 (222.2mm) 73 ⁄ 4 (196.8mm) Product Range: 3 ⁄ 4” to 2” Pinion Speed: 900 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

Kodiak 200 Plus Medium Chamber Mantle: 406051X Bowl Liner: 406055X A 7 (177.8mm) 63 ⁄ 4 (171.4mm) 1 2 (165.1mm) 6 ⁄ 63 ⁄ 8 (161.9mm) 61 ⁄ 4 (158.8mm)

All Dimensions in Inches

B

C

53 ⁄ 4 (146mm) 53 ⁄ 4 (146mm) 51 ⁄ 4 (133.3mm) 53 ⁄ 16 (131.8mm) 5 (127mm)

1 4 (31.7mm) 1 ⁄ 1 1 ⁄ 8 (28.6mm) 7

⁄ 8 (22.2mm) 3 ⁄ 4 (19mm) 5 ⁄ 8 (15.9mm)

Product Range: 5 ⁄ 8” to 1” Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

39

C R U S H I N G

Kodiak 200 Plus Fine Chamber

Mantle: 406052X Bowl Liner: 406056X All Dimensions in Inches A B C 1 7 8 (79.4mm) 6 (152.4mm) 3 ⁄ ⁄ 8 (22.2mm) 1 5 2 (114.3mm) ⁄ 8 (15.9mm) 4 ⁄ 3 (76.2mm) 1 1 2 (114.3mm) 4 ⁄ 27 ⁄ 8 (73mm) ⁄ 2 (12.7mm) 1 3 2 (114.3mm) ⁄ 8 (9.5mm) 4 ⁄ 23 ⁄ 4 (69.8mm) Product Range: 3 ⁄ 8” to 3 ⁄ 4” Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

Kodiak 200 Plus Medium Chamber with Feed Slots Mantle: 406051X Bowl Liner: 406054X All Dimensions in Inches A B C 1 1 2 (215.9mm) 4 (31.7mm) 8 ⁄ 71 ⁄ 2 (190.5mm) 1 ⁄ 1 8 (28.6mm) 81 ⁄ 4 (209.5mm) 71 ⁄ 4 (184.2mm) 1 ⁄ 7 8 (203.2mm) 7 (177.8mm) ⁄ 8 (22.2mm) 3 ⁄ 4 (19mm) 77 ⁄ 8 (200mm) 67 ⁄ 8 (174.6mm) 5 ⁄ 8 (15.9mm) 73 ⁄ 4 (196.8mm) 63 ⁄ 4 (171.4mm) Product Range: 5 ⁄ 8” to 1” Pinion Speed: 900 RPM Reduction Ratio: 4:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

40

C


R U S H I N G

Crusher Closed Side Setting Product 5 ⁄ 16” Size 7.94 mm

3

⁄ 8” 7 ⁄ 16” 1 ⁄ 2”

5

⁄ 8”

3

⁄ 4”

7

⁄ 8”

1”

9.52 11.11 12.7 15.87 19.05 22.22 25.4 mm mm mm mm mm mm mm

11 ⁄ 4” 11 ⁄ 2” 13 ⁄ 4” 32 mm

38.1 44.5 mm mm

4”

2” 50.8 mm 100

1 3 ⁄ 2”

100

96

3”

100

95

90

23 ⁄ 4”

98

92

86

1 2 ⁄ 2”

100

95

88

81

1 2 ⁄ 4”

97

91

83

74

100

94

86

76

65

100

99

89

79

66

55

100

99

97

82

68

56

45

100

99

95

90

72

56

46

38

100

99

95

87

79

60

45

36

29

100

99

95

88

80

70

49

38

30

25

100

97

95

91

83

71

61

41

32

26

21

2” 13 ⁄ 4” 1 1 ⁄ 2” 1 1 ⁄ 4”

1” 7 8” ⁄ 3 4” ⁄ 5 ⁄ 8”

100

98

94

90

85

73

58

49

34

28

22

18

1 2” ⁄

99

95

89

85

75

63

50

42

28

23

19

16

3 ⁄ 8”

91

85

75

69

63

51

42

33

21

17

14

12

5 16” ⁄

85

75

65

61

56

43

35

27

19

15

13

10

1 4” ⁄

74

63

52

50

45

37

29

23

16

13

11

9

4M

58

51

42

36

33

28

21

18

14

11

9

7

5 32” ⁄

50

42

36

30

28

23

18

15

12

10

8

6

8M

40

35

30

26

24

20

16

12

9

7

5

4

10M

35

31

26

22

20

17

14

10

8

6

4

3

16M

28

24

21

17

15

13

10

8

6

4

3

2

30M

21

18

15

11

9

8

6

5

4

3

2

1.5

40M

18

15

13

10

8

7

5

4

3

2

1.5

1

50M

14

12

11

8

7

6

4

3

2

1.5

1

0.8

100M

11

9

8

7

6

5

4

3

1.5

1

0.5

0.5

200M

8

7

6

6

5

4

3

2

1

0.5

0.5

0.3


41

C


R U S H I N G

A

B


Mantle: 456262X Bowl Liner: 456394X A 1 8 (257.1mm) 10 ⁄ 101 ⁄ 4 (260.3mm) 103 ⁄ 8 (263.5mm) 101 ⁄ 2 (266.7mm) 103 ⁄ 4 (273mm) 11 (279.4mm) 111 ⁄ 4 (285.8mm) 1 Product Range: 1” to 2 ⁄ 2”

C


B

C

91 ⁄ 4 (234.9mm) 93 ⁄ 8 (238.1mm) 1 2 (241.3mm) 9 ⁄ 95 ⁄ 8 (244.4mm) 93 ⁄ 4 (274.6mm) 10 (254mm) 101 ⁄ 4 (260.3mm)

3

⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm) 11 ⁄ 4 (31.7mm) 11 ⁄ 2 (38.1mm) 13 ⁄ 4 (44.4mm) 2 (50.8mm)

Pinion Speed: 850 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

Kodiak 300 Plus Medium Coarse Chamber

A

B

C

Mantle: 456262X Bowl Liner: 45695X A 83 ⁄ 4 (222.2mm) 9 (228.6mm) 9 (228.6mm) 93 ⁄ 8 (238.1mm) 95 ⁄ 8 (244.4mm) 97 ⁄ 8 (250.8mm) 1 Product Range: 3 ⁄ 4” to 1 ⁄ 2”


B

73 ⁄ 4 (196.8mm) 73 ⁄ 4 (196.8mm) 8 (203.2mm) 81 ⁄ 4 (209.5mm) 81 ⁄ 2 (215.9mm) 83 ⁄ 4 (222.2mm)

C 3

⁄ 4 (19mm)) 7 ⁄ 8 (22.2mm) 1 (25.4mm) 11 ⁄ 4 (31.7mm) 11 ⁄ 2 (38.1mm) 13 ⁄ 4 (44.4mm)


42

C Kodiak 300 Plus Medium Chamber with Feed Slots Mantle: 456262X Bowl Liner: 45696X A 87 ⁄ 8 (225.4mm) 9 (228.8mm) 91 ⁄ 8 (231.8mm) 91 ⁄ 4 (234.9mm) 91 ⁄ 2 (241.3mm) 3 4” Product Range: 3 ⁄ 4” to 1 ⁄

A

R U S H I N G

B

C


B

C

77 ⁄ 8 (200mm) 8 (203.2mm) 81 ⁄ 8 (206.4mm) 81 ⁄ 4 (209.5mm) 1 8 ⁄ 2 (215.9mm)

5

⁄ 8 (15.9mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm) 2 (50.8mm)


A

Kodiak 300 Plus Medium Chamber

Mantle: 456262X Bowl Liner: 456395X A 75 ⁄ 8 (193.7mm) 73 ⁄ 4 (196.8mm) 77 ⁄ 8 (200mm) 8 (203.2mm) 81 ⁄ 4 (209.5mm)

B

C


B 61 ⁄ 2 (165.1mm) 65 ⁄ 8 (168.2mm) 63 ⁄ 4 (171.4mm) 67 ⁄ 8 (174.6mm) 71 ⁄ 8 (180.9mm)

C 5

⁄ 8 (15.9mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm) 13 ⁄ 4 (44.4mm)

3 3 4” to 1 ⁄ 4” Product Range: ⁄ Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

43

C R U S H I N G

Kodiak 300 Plus Medium Fine Chamber

Mantle: 456262X Bowl Liner: 456397X A 51 ⁄ 8 (130.2mm) 51 ⁄ 4 (133.3mm) 53 ⁄ 8 (136.5mm) 51 ⁄ 2 (138.7mm) 55 ⁄ 8 (142.9mm)

A

B

C


B 35 ⁄ 8 (92mm) 33 ⁄ 4 (96.3mm) 37 ⁄ 8 (98.4mm) 4 (101.6mm) 41 ⁄ 8 (104.8mm)

C 1

⁄ 2 (12.7mm) 5 ⁄ 8 (15.9mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm)

1 7 Product Range: ⁄ 2” to ⁄ 8” Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

B

Kodiak 300 Plus Fine Chamber Mantle: 456322X Bowl Liner: 456398X A 43 ⁄ 8 (111.1mm) 41 ⁄ 2 (114.3mm) 45 ⁄ 8 (117.5mm) 43 ⁄ 4 (120.7mm) 47 ⁄ 8 (123.8mm) 5 (127mm) 3 5 4” to ⁄ 8” Product Range: ⁄

A

C


B 23 ⁄ 4 (69.8mm) 27 ⁄ 8 (73mm) 3 (76.2mm) 31 ⁄ 8 (79.4mm) 31 ⁄ 4 (82.5mm) 33 ⁄ 8 (85.7mm)

C 1

⁄ 4 (6.4mm) 3 ⁄ 8 (9.5mm) 1 ⁄ 2 (12.7mm) 5 ⁄ 8 (15.9mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm)


44

C


R U S H I N G

Crusher Closed Side Setting Product 5 ⁄ 16” Size 7.94 mm

3

⁄ 8” 7 ⁄ 16” 1 ⁄ 2”

5

⁄ 8”

3

⁄ 4”

7

⁄ 8”

1”

9.52 11.11 12.7 15.87 19.05 22.22 25.4 mm mm mm mm mm mm mm

11 ⁄ 4” 11 ⁄ 2” 13 ⁄ 4” 32 mm

38.1 44.5 mm mm

4”

2” 50.8 mm 100

1 3 ⁄ 2”

100

96

3”

100

95

90

23 ⁄ 4”

98

92

86

1 2 ⁄ 2”

100

95

88

81

1 4” 2 ⁄

97

91

83

74

100

94

86

76

65

100

99

89

79

66

55

100

99

97

82

68

56

45

100

99

95

90

72

56

46

38

100

99

95

87

79

60

45

36

29

100

99

95

88

80

70

49

38

30

25

100

97

95

91

83

71

61

41

32

26

21

5 100 8” ⁄

98

94

90

85

73

58

49

34

28

22

18

1 2” ⁄

99

95

89

85

75

63

50

42

28

23

19

16

3 8” ⁄

91

85

75

69

63

51

42

33

21

17

14

12

5 16” ⁄

85

75

65

61

56

43

35

27

19

15

13

10

1 4” ⁄

74

63

52

50

45

37

29

23

16

13

11

9

4M

58

51

42

36

33

28

21

18

14

11

9

7

5 32” ⁄

50

42

36

30

28

23

18

15

12

10

8

6

8M

40

35

30

26

24

20

16

12

9

7

5

4

10M

35

31

26

22

20

17

14

10

8

6

4

3

16M

28

24

21

17

15

13

10

8

6

4

3

2

30M

21

18

15

11

9

8

6

5

4

3

2

1.5

40M

18

15

13

10

8

7

5

4

3

2

1.5

1

50M

14

12

11

8

7

6

4

3

2

1.5

1

0.8

100M

11

9

8

7

6

5

4

3

1.5

1

0.5

0.5

200M

8

7

6

6

5

4

3

2

1

0.5

0.5

0.3

2” 13 ⁄ 4” 1 2” 1 ⁄ 1 1 ⁄ 4”

1” 7 8” ⁄ 3 4” ⁄


45

C


R U S H I N G

A

B

Kodiak 400 Plus Coarse Chamber Mantle: 546034X Bowl Liner: 546745X A 111 ⁄ 2 (292.1mm) 115 ⁄ 8 (295.3mm) 113 ⁄ 4 (298.4mm) 12 (304.8mm) 121 ⁄ 4 (311.2mm) 121 ⁄ 2 (317.5mm) 123 ⁄ 4 (323mm) 1 2” Product Range: 1” to 2 ⁄

C


B

C

101 ⁄ 4 (260.3mm) 103 ⁄ 8 (263.5mm) 1 10 ⁄ 2 (266.7mm) 103 ⁄ 4 (273.1mm) 1 11 ⁄ 8 (282.6mm) 113 ⁄ 8 (288.9mm) 111 ⁄ 2 (292.1mm)

3

⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm) 11 ⁄ 4 (31.7mm) 11 ⁄ 2 (38.1mm) 13 ⁄ 4 (44.4mm) 2 (50.8mm)


Kodiak 400 Plus Medium Chamber with Feed Slots

Mantle: 546034X Bowl Liner: 546747X

A

B

C


A

B

91 ⁄ 2 (241.3mm) 95 ⁄ 8 (244.4mm) 93 ⁄ 4 (274.6mm) 97 ⁄ 8 (250.8mm) 101 ⁄ 4 (260.3mm)

81 ⁄ 8 (206.3mm) 81 ⁄ 4 (209.5mm) 83 ⁄ 8 (212.7mm) 81 ⁄ 2 (215.9mm) 83 ⁄ 4 (222.2mm)

C 5

⁄ 8 (15.9mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm) 11 ⁄ 4 (31.7mm)

Product Range: 3 ⁄ 4” to 11 ⁄ 4” Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

46

C Kodiak 400 Plus Medium Chamber

A

R U S H I N G

B

C



A

B

C

81 ⁄ 8 (206.3mm) 81 ⁄ 4 (209.5mm) 83 ⁄ 8 (212.7mm) 81 ⁄ 2 (215.9mm) 83 ⁄ 4 (222.2mm) 1 Product Range: 3 ⁄ 4” to 1 ⁄ 4”

65 ⁄ 8 (168.2mm) 63 ⁄ 4 (171.4mm) 67 ⁄ 8 (174.6mm) 7 (177.8mm) 73 ⁄ 8 (187.3mm)

5

⁄ 8 (15.9mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm) 11 ⁄ 4 (31.7mm)



A

B

C

Mantle: 546034X Bowl Liner: 546748X A 51 ⁄ 4 (133.4mm) 53 ⁄ 8 (135.5mm) 51 ⁄ 2 (139.7mm) 53 ⁄ 4 (146mm) 57 ⁄ 8 (149.2mm) 1 7 Product Range: ⁄ 8 to ⁄ 8”


B

31 ⁄ 2 (88.9mm) 33 ⁄ 4 (95.3mm) 37 ⁄ 8 (98.4mm) 4 (101.6mm) 41 ⁄ 8 (104.8mm)

C 1

⁄ 2 (12.7mm) 5 ⁄ 8 (15.9mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (25.4mm)

Pinion Speed: 900 to 950 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

47

C R U S H I N G


A

B

C



A

B

37 ⁄ 8 (98.4mm) 4 (101.6mm) 41 ⁄ 8 (104.8mm) 41 ⁄ 4 (107.9mm) 43 ⁄ 8 (111.1mm)

21 ⁄ 8 (54mm) 21 ⁄ 4 (57.2mm) 23 ⁄ 8 (60.3mm) 21 ⁄ 2 (63.5mm) 25 ⁄ 8 (66.7mm)

C 1

⁄ 4 (6.3mm) 3 ⁄ 8 (9.5mm) 1 ⁄ 2 (12.7mm) 5 ⁄ 8 (15.9mm) 3 ⁄ 4 (19mm)

Product Range: 1 ⁄ 4” to 5 ⁄ 8” Pinion Speed: 950 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

48

C A

Kodiak 500 Plus Extra Coarse Chamber

R U S H I N G

B

C

Mantle: 606100SX Bowl Liner: 606105SX


A

B

C

14 (356mm) 141 ⁄ 4 (362mm) 143 ⁄ 8 (365mm) 143 ⁄ 4 (375mm) 151 ⁄ 16 (383mm) Product Range: 11 ⁄ 2” to 3

13 (330mm) 131 ⁄ 16 (332mm) 133 ⁄ 8 (340mm) 137 ⁄ 8 (352mm) 141 ⁄ 16 (357mm)

11 ⁄ 4 (32mm) 11 ⁄ 2 (38mm) 2 (51mm) 21 ⁄ 2 (64mm) 3 (76mm)

Pinion Speed: 830 - 890 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)


A

B

C



A

B

121 ⁄ 2 (317mm) 125 ⁄ 8 (321mm) 1215 ⁄ 16 (329mm) 131 ⁄ 4 (337mm) 133 ⁄ 4 (349mm) Product Range: 3 ⁄ 4” to 3”

111 ⁄ 8 (283mm) 111 ⁄ 2 (292mm) 113 ⁄ 4 (298mm) 121 ⁄ 8 (308mm) 123 ⁄ 4 (324mm)

C 3

⁄ 4 (19mm)

1 (25.4mm) 11 ⁄ 4 (32mm) 11 ⁄ 2 (38mm) 2 (51mm)


49

C R U S H I N G

Kodiak 500 Plus Medium Chamber

A

B

C

Mantle: 606100SX Bowl Liner: 606111SX A 113 ⁄ 4 (298mm) 117 ⁄ 8 (302mm) 12 (305mm) 121 ⁄ 8 (308mm) 123 ⁄ 8 (314mm)


B

101 ⁄ 2 (267mm) 105 ⁄ 8 (270mm) 103 ⁄ 4 (273mm) 107 ⁄ 8 (276mm) 111 ⁄ 8 (283mm)

C 5

⁄ 8 (16mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22.2mm) 1 (19mm) 1 4 (32mm) 1 ⁄

Product Range: 5 ⁄ 8” to 2” Pinion Speed: 830 - 890 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)


Mantle: 606100SX Bowl Liner: 606315SX A 63 ⁄ 8 (162mm) 61 ⁄ 2 (165mm) 65 ⁄ 8 (168mm) 63 ⁄ 4 (171mm) 67 ⁄ 8 (175mm)

B A

C


B 45 ⁄ 8 (117mm) 43 ⁄ 4 (121mm) 47 ⁄ 8 (124mm) 51 ⁄ 16 (129mm) 51 ⁄ 4 (133mm)

C 1

⁄ 2 (13mm) 5 ⁄ 8 (16mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22mm) 1 (25mm)

Product Range: 1 ⁄ 2” to 1” Pinion Speed: 830 - 890 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

50 50


C R U S H I N G

B A

C



A

B

105 ⁄ 8 (270mm) 103 ⁄ 4 (273mm) 107 ⁄ 8 (276mm) 11 (279mm) 111 ⁄ 8 (283mm) Product Range: 1 ⁄ 2" to 1"

93 ⁄ 8 (238mm) 91 ⁄ 2 (241mm) 95 ⁄ 8 (244mm) 93 ⁄ 4 (248mm) 97 ⁄ 8 (251mm)

C 1

⁄ 2 (13mm) 5 ⁄ 8 (16mm) 3 ⁄ 4 (19mm) 7 ⁄ 8 (22mm) 1 (25mm)


Kodiak 500 Plus Extra Fine Chamber

B A

C



A

B

41 ⁄ 2 (114mm) 45 ⁄ 8 (118mm) 43 ⁄ 4 (121mm) 47 ⁄ 8 (124mm) 5 (127mm) Product Range: 1 ⁄ 4" to 3 ⁄ 4"

25 ⁄ 8 (66.7mm) 23 ⁄ 4 (70mm) 3 (76mm) 31 ⁄ 8 (79mm) 31 ⁄ 4 (83mm)

C 1

⁄ 4 (6mm) 3 ⁄ 8 (10mm) 1 ⁄ 2 (13mm) 5 ⁄ 8 (16mm) 3 ⁄ 4 (19mm)


51

C

NOTES:

R U S H I N G

52

C

) ) ) ) h h h h p p p p t t t t 5 0 5 0 m m m m 8 6 2 3 m 3 4 6 8 0 7 7 3 ” - 5 0 - 1 0 - 6 0 - 5 m 0 2 1 3 4 5 7 - 0 5 7 5 0 - 3 - 6 3 2 5 4 5 0 7 3 5 9 2 3 4 5 ( ( ( ( ) ) ) ) h h h h p p p p t t t t 5 0 5 5 m m m m 6 4 9 3 ” 3 4 5 7 4 m 1 9 0 7 ⁄ - 3 0 - 9 5 - 4 5 - 6 3 m 5 4 3 6 1 4 8 5 3 7 5 - 3 - 4 - 9 2 9 5 0 8 1 5 1 3 4 2 3 4 5 ( ( ( ( ) ) ) ) h h h h p p p p t t t t 5 5 0 0 m m m 6 1 5 7 m ” 3 4 5 6 2 m 1 6 9 ⁄ - 3 0 - 7 0 - 9 5 - 8 m 0 1 8 0 3 3 4 6 1 3 6 3 4 4 2 6 3 9 4 9 5 4 3 9 9 9 2 2 3 4 ( ( ( ( ) ) ) ) h h h h p p p p t t t t 5 5 5 5 r m m m m 4 8 0 8 ” 3 3 5 5 4 m u 3 0 8 1 ⁄ m 0 1 0 5 5 5 5 3 1 2 o 3 3 4 5 1 3 4 - 1 - 0 - 8 2 3 4 4 H 8 1 7 0 1 8 6 4 r 2 2 3 4 ( ( ( ( e P ) ) ) ) h h h h s p p p p t t t t n 0 0 5 0 m m m m o 3 2 2 m 2 3 3 4 5 0 9 6 2 ” T - 9 0 - 9 0 - 8 5 - 7 m 1 0 5 2 2 3 4 7 - 4 n 2 2 - 2 - 2 i 2 0 3 8 4 6 5 0 4 0 8 s 2 2 3 3 ( ( ( ( e i t i ) ) ) ) c h h h h a p p p p t t t t p 5 0 5 5 m m m m 4 0 9 9 a m ” 2 3 3 4 2 2 8 9 8 m ⁄ 2 0 2 C 7 5 3 5 0 4 0 7 2 2 4 t 8 4 1 2 - 9 i 1 2 3 3 3 8 6 4 u 6 1 8 5 1 2 2 3 c ( ( ( ( r i ) ) ) ) C h h h h p p p p n t t t t 0 0 5 5 e m m m m 7 6 4 m 2 p 2 2 3 4 ” 0 5 1 4 - 0 5 - 4 0 - 3 5 - 0 4 m 5 ⁄ 3 9 O 2 2 3 7 4 1 6 - 1 - 9 - 3 1 0 2 5 2 3 0 5 9 6 4 1 1 2 3 ( ( ( ( ) ) ) ) h h h h p p p p t t t t 5 0 5 5 m m m m 9 4 1 9 m 1 7 2 8 3 6 3 8 ” 8 m ⁄ 6 0 1 7 0 1 8 5 0 0 5 2 2 3 9 5 2 1 4 1 7 1 2 3 7 3 0 2 7 2 9 1 1 2 2 ( ( ( ( ) ) ) ) h h h h p p p p t t t t 5 0 0 0 m m m m 6 1 6 3 m 1 0 2 1 2 6 3 9 ” 2 m 5 5 0 9 0 3 0 9 ⁄ 3 1 1 2 7 1 7 2 1 2 - 1 - 1 - 2 1 3 2 1 4 5 1 5 9 4 1 1 1 2 ( ( ( ( s s s s s s s s t t t o o o o r u r r r t u u u p p p p G G G G g d ) h h h h n e e S s s s s i s d t u g u g u g u g S i t l l l l u u u u o l C e S o o o o P P P P ( r r r r C S 0 0 0 0 h h h h 0 T 0 T 0 T 0 T 2 3 4 5 K K K K

R U S H I N G

S T R A H C N O I T A D A R G D N A Y T I C A P A C D E T C E J O R P R E H S U R C E N O C S E I R E S S U L P K A I D O K

53 53

C

) ) ) ) h h h h p p p p t t t t 8 7 4 1 m m m m 4 7 6 2 ” 2 2 3 4 4 m 5 1 0 2 ⁄ - 2 3 - 5 2 - 3 9 - 8 m 4 1 2 2 2 3 3 1 7 - 2 3 1 - 9 - 4 2 2 2 5 3 7 8 5 0 6 1 1 2 2 3 ( ( ( (

R U S H I N G

S T R A H C N ) ) ) ) h h h h O p p p p I t t t t 3 1 6 1 m m m m T 5 6 3 1 m 2 2 3 4 9 7 5 3 ” - 2 3 - 3 9 - 0 6 - 7 A 1 m 4 5 2 2 3 3 7 - 1 2 1 - 6 - 3 D 2 4 2 4 3 5 8 5 9 4 0 A 1 1 2 3 ( ( ( ( R G D N ) ) ) ) A h h h h p p p p t t t t r 6 0 6 6 Y m m m m 9 4 3 9 u m 1 8 2 8 3 7 3 9 T ” - 7 2 - 1 9 - 8 2 - 5 o 8 m 4 I ⁄ 7 2 1 2 2 4 9 6 1 H 2 1 1 C - 1 4 - 2 9 - 3 3 3 r 3 7 2 8 A e 1 1 2 2 ( ( ( ( P P A C s n o D T E ) ) ) ) n i h h h h T p p p p t t t t s C 3 4 3 9 m m m e 8 2 0 6 m 1 6 2 3 3 5 3 m i E ” t 5 - 6 8 - 0 1 - 7 1 - 3 4 m 7 ⁄ J i 3 9 c 1 2 2 3 7 - 4 1 3 - 1 - 1 1 4 2 8 3 2 O a 2 2 6 1 8 p R 1 1 2 2 a ( ( ( ( P C t i R u E i c r H ) ) ) ) S C h h h h p p p p t t t t U d 6 4 8 6 e m m m m 6 2 6 3 m R s ” 1 2 2 3 0 5 3 5 - 5 2 - 8 3 - 4 2 - 0 8 m 9 ⁄ o C l 5 6 1 1 2 7 3 1 1 - 6 - 1 - 2 1 1 2 C 8 7 3 7 E 0 4 9 4 1 1 1 2 ( ( ( ( N O C S E I ) ) ) ) h h h h p p R p t t t t 9 m 1 m 1 p 0 E m 4 7 2 8 m 1 m 1 2 2 0 2 4 ” S 2 m 6 7 5 6 9 0 0 5 ⁄ 2 1 3 1 2 0 4 7 2 3 1 S 1 1 1 1 2 1 2 8 5 3 6 0 9 U 1 1 2 ( ( ( ( L P K A I t t t t e t e e e t D t t u u u u N N N N p p p p g O d ) s s s s h h h h n e e S u u u u i K s d t l g l g l g l g S t P u o i l e S ( 0 o r C S C 0 h 2 T K

54

P u o 0 r 0 h 3 T K

P u o 0 r 0 h 4 T K

P u o 0 r 0 h 5 T K

” % 4 m ⁄ m 8 1 1 2 3 2

% 8 2

% 8 2

% 8 2

S T R A H C N m % % % % O ” I 1 1 1 1 m 5 1 2 2 2 2 T 2 A D A R G D m N ” % % % 8 m % ⁄ 0 0 0 0 A 7 2 2 2 2 2 2 Y T I C A P A C d ” m % % % % 4 m 7 ⁄ 7 7 7 D a 3 9 1 1 1 o 1 1 E L T g C n i E t J l O a u c R i P r c m ” % % % e 8 m % ⁄ 5 5 5 5 5 6 R 1 1 1 1 R 1 E H S U R C E m % % % % ” N 2 m 5 ⁄ 3 5 5 5 1 1 1 1 O 1 1 C S E I R E S m % % % % ” S 8 m 5 ⁄ 0 5 5 5 3 1 1 1 U 1 1 L P K A I d d d d a a a a D o o o o L L L L s s s O u g u g u g g n l n l n l n n ) e e g P i P i P i S 0 i K d i 0 t t t s t S i t a 0 a 0 a 2 o d l l l l C e S 0 0 K ( u u u C S 3 4 c c c r r r K K i i i c c c e e e R R R

t 0 a l 0 5 u c r K i c e R

n e e r c s o t y t i l i b a , l a i r e t a m d e e f f o e r u t a n s a s r o t c a f h c u s y b d e c n e u l f n i e r . a t a d o n l f a l i t w o p b o t e t i c p u d n m i o t r f o n y r s a e v o l d i t w a h t s r e e l b b i m s u s n o p n o i g t n c i t u t d e s o r t p s e d s n o l c a . g e n n i h o i t t t t i s e i d s n g e o n d i c i t s t e e s s d e e n e s a d o i s l c g n a d m e u m s o d l m c i n n a i m m s e u l n i m a f i u n t t i c M A u o

. d t e n e d n m p e i m u m q e o c g r n e i n n i e h e t i r c s w n d o n i a t a r g e n i p h o s u e r n c i h f o c a n m o i t n a o c d i l p e s p a a b d n c a e n s a n o m i r t i o f d r n e o p c d g e n t i a t a m r i t e s p o e n s i w s o n h o s i t a t u i b r a v y t . n y o l t a n r r e o a u d w s e s a d t o e a i l d p p r u d m e i p h g r s n i o i l t b a d u e m p s i t s s m e e r o r r p f x f o r e e n n f f o i i t d a e a y a t m u t r i m t o f s s n t n i l o u s c i s t h e t r o n e d s e s t U a e . o s d m r i t e n t s o e E i t : T a m a r m N r A o a p T f n R i n g O s i P i s h e M I T d

C R U S H I N G

55 55

C

NOTES:

R U S H I N G

56

” 2

S T R A H C N O I T A D A R G D N A r u Y o T I H C r e A P P s A n C T o D n i E T s e C i t i E J c O a p a R P C t i u R c r E i H S C e U n p R O C E N O C S L 0 0 4 1 / S L 0 0 2 1

5 0 8 8 4 m 3 0 m 7 0 2 3 3

5 0 6 5 ” 8 3 4 4 0 . ⁄ m 3 5 m 0 5 1 6 2 1 3 5 0 5 4 ” 5 3 4 2 . m - ⁄ 1 5 4 m 0 1 4 4 2 9 2 0 0 2 9 ” 1 3 3 4 . m ⁄ 1 8 0 5 1 3 m 2 2 6 2 0 0 7 5 2 3 ” m 2 1 3 m 0 0 0 2 4 2

5 5

4 0 4 ” 2 3 . m 8 5 ⁄ 0 7 2 m 8 0 3 1 2

0 5 2 8 2 ” . m 2 - 2 4 2 ⁄ 2 5 5 3 m 2 6 1 2 2 5 5

5 5 9 ” 1 2 0 m . 8 - ⁄ 5 9 1 m 0 4 0 0 1 2

5 5

1 7 6 ” 1 2 m . 2 8 ⁄ 5 m 2 5 0 1 1 7 1 1

7 . 2 1

S S L L 0 0 0 0 2 1 4 1

t u p d ) s h e e S s g s o S i u o d r l C o ( G r C S g n h i t T t e S

, l a i r e t a m d e e f f o 0 5 6 0 e 0 7 1 7 r 4 3 3 2 2 . % ” m u 5 8 1 2 m 2 2 t 5 6 5 2 1 a 6 9 2 2 1 1 n s a s r o t 5 5 4 8 c 7 3 0 4 2 ” 2 3 2 2 2 a % m . 8 - 5 - 2 - 1 f ⁄ 6 5 7 2 m 2 2 0 5 8 2 4 2 1 1 h c u s y b d 0 5 0 2 e 5 1 0 5 5 ” c 2 3 2 2 0 % m . - 0 - 8 - 2 4 9 ⁄ 0 5 3 m 2 8 4 4 9 n e 1 r 1 2 1 1 l u u f n o i . H e t r a r a o e 0 0 6 4 l f d 2 8 7 2 7 P 2 2 1 2 l 8 % n m - ” . 8 a 5 m 0 5 5 2 0 s ⁄ 5 1 w 2 6 2 3 8 o i t n 1 2 1 1 b p . o e T o e t c r t n u u i i s d p s s n 0 5 2 8 i e e 9 3 5 8 m i r 7 t ” 1 2 1 1 . t % m o 2 2 i 1 ⁄ o r p 5 0 6 2 c 1 m 0 f 2 4 n 9 5 1 m a 1 1 1 1 s y e r p e t a a o s v y d l C s t i t f i a w i e 5 0 0 h u 2 4 9 6 t l s 2 2 c 1 1 e m % r ” - 1 - 1 - l 8 5 e r ⁄ . i 6 r e 5 5 2 3 9 m 1 7 1 4 2 b b C 9 w 1 1 1 i s m o d l s u e o d s p n n n o a l g o i , n 5 0 3 i t n C ” 4 5 4 t 0 2 c 1 t 6 o m % 1 - 9 - 1 u i 1 9 . 5 ⁄ t 5 7 5 7 m 1 0 1 7 8 e d i 9 1 9 s o d t r s p n e o s c d o n l c a e s e g e 0 7 n n 5 m % 9 h ” 7 i a t 4 3 t ⁄ . m 1 5 5 4 t 1 6 s e g 7 6 i n s a g e m n i d , t i t s s e e d s n i e S S S S e f L s L L L d 0 0 0 o t 0 i l 0 0 0 u 0 s 2 4 c 1 4 1 2 1 1 d o n m e e s u e o r l m i c g c t t n n u u i i s t p p g d ) s m a h h o d e i l e n t S s m t u a g g s e d u t o S l t o u u c o i r N l y e C r L G o o m a t ( i r r i C S S i c u l h h n t e i T T i c b R M A a

C R U S H I N G

57

C

1200 LS / 1400 LS CONE CRUSHER GRADATION CHART

R U S H I N G

Crusher Closed Side Setting 5 3 7 1 5 3 7 1 1 3 Product ⁄ 16” ⁄ 8” ⁄ 16” ⁄ 2” ⁄ 8” ⁄ 4” ⁄ 8” 1” 1 ⁄ 4” 1 ⁄ 2” 1 ⁄ 4” 2” Size 7.94 9.52 11.11 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

4”

100

1 3 ⁄ 2”

100

96

3”

100

95

90

23 ⁄ 4”

98

92

86

1 2” 2 ⁄

100

95

88

81

1 2 ⁄ 4”

97

91

83

74

100

94

86

76

65

100

97

88

79

66

55

100

96

91

80

68

56

45

100

97

90

83

70

56

46

38

100

99

90

82

72

58

45

36

29

100

99

93

86

74

64

48

38

30

25

2” 13 ⁄ 4” 1 1 ⁄ 2” 1 4” 1 ⁄

1” 7 ⁄ 8” 3 4” ⁄

100

97

94

87

80

65

54

40

32

26

21

5 8” ⁄

98

94

87

80

69

55

46

34

28

22

18

1 2” ⁄

100

95

88

80

69

58

47

39

28

23

19

16

3 8” ⁄

91

84

73

63

52

44

37

28

21

17

14

12

5 ⁄ 16”

85

74

63

54

46

37

31

25

19

15

13

10

1 4” ⁄

74

61

50

44

36

32

26

21

16

13

11

9

4M

58

48

42

35

32

26

21

18

14

11

9

7

5 32” ⁄

50

41

36

30

28

23

18

15

12

10

8

6

8M

40

35

30

26

24

20

16

12

9

7

5

4

10M

35

31

26

22

20

18

14

10

8

6

4

3

16M

28

24

21

17

15

13

10

8

6

4

3

2

30M

20

18

15

11

9

8

6

5

4

3

2

1.5

40M

18

15

14

10

8

7

5

4

3

2

1.5

1

50M

14

12

12

8

7

6

4

3

2

1.5

1

0.8

100M

11

9

9

7

6

5

4

3

1.5

1

0.5

0.5

200M

8

7

6

6

5

4

3

2

1

0.5

0.5

0.3


58

mm

C

LS SERIES CRUSHER MANGANESE CONFIGURATIONS

R U S H I N G

1200LS Enlarged Feed Coarse Chamber Bowl Liner: 450127 All Dimensions in Inches Mantle: 450263 A B C Max. Feed Material 10 83 ⁄ 4 2 93 ⁄ 8 1 2 91 ⁄ 2 83 ⁄ 8 1 ⁄ 9 1 91 ⁄ 4 81 ⁄ 8 1 ⁄ 81 ⁄ 8 4 9 77 ⁄ 8 1 8.4 Product Range: 1” to 2” Minus Pinion Speed: 750 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

1200LS Coarse Chamber

Bowl Liner: 450127 All Dimensions in Inches Mantle: 450128 A B C Max. Feed Material 93 ⁄ 4 9 2 93 ⁄ 8 1 91 ⁄ 2 81 ⁄ 2 1 ⁄ 9 2 1 4 91 ⁄ 4 81 ⁄ 4 1 ⁄ 83 ⁄ 4 9 8 1 8.5 1 Product Range: 3 ⁄ 4” to 1 ⁄ 2” Minus Pinion Speed: 750 to 850 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

59

C R U S H I N G

1200LS Medium Fine Chamber

Bowl Liner: 450177 All Dimensions in Inches Mantle: 450128 A B C Max. Feed Material 1 4 5 ⁄ 4 1 45 ⁄ 8 7 1 2 ⁄ 8 51 ⁄ 8 37 ⁄ 8 4 ⁄ 3 ⁄ 4 5 33 ⁄ 4 43 ⁄ 8 1 ⁄ 2 43 ⁄ 4 33 ⁄ 4 4 1 1 2” to ⁄ 2” Minus Product Range: ⁄ Pinion Speed: 800 to 900 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

60

C B U J J J J H

B U J J J J H

R E V O T A O E H M S 0 0 0 0 . . . . E 6 7 8 9 V 1 1 1 A - 1 E V V V V H S 8 - 8 - 8 - 8 -

R E V O T A O E H M S 5 5 . 2 . 0 . 2 . E 2 3 4 V 1 1 1 A - 1 E V V V V H S 8 - 8 - 8 - 8 -

6 6 6 6

R U S H I N G

8 8 8 8

R 6 6 6 6 E ⁄ E 1 ⁄ 1 ⁄ 1 ⁄ 1 O R R 5 5 5 5 T 1 1 1 1 O O B 2 2 2 2 B O M E L G E E L L N I G G S N N I R R E – I S E S E E V V B B H A A P H P A S S U E H M M M M H U E U T H U H N N N N H H R S A 0 R 0 C S C 0 D 0 2 2 E – – V I R R R O O D T T 8 8 8 8 8 O O T . . . . . 0 0 0 E E 4 4 4 4 4 L M M 3 3 3 V V - V - V - 2 2 2 2 2 E A A V M M E V V V V E 8 8 8 V B - P H 8 8 8 8 P H - - - 8 S - - - - R S 8 8 8 V R 6 6 6 6 0 8 0 S 0 0 L 2 8 0 1 1 0 2 1 I M M M M M M M M C P P P P P P P P J R R R R R R R R I 5 5 5 5 0 0 0 0 P 2 7 2 7 5 0 5 0 K 7 7 8 8 7 8 8 9 D E E P S

D E E P S

N O I N I P

N O I N I P

E E E M N S U N I F I I R / F / A D D E X O E C M M E

S R E N I L

E N I F

E E E M N S U N I F I I R / F / A D D E X O E C M M E

S R E N I L

E N I F 61

C R U S H I N G

1400LS Coarse Chamber

Bowl Liner: 540113 All Dimensions in Inches Mantle: 540101 A B C Max. Feed Material 12 111 ⁄ 4 2 115 ⁄ 8 1 2 111 ⁄ 4 103 ⁄ 4 1 ⁄ 11 1 4 11 101 ⁄ 2 1 ⁄ 8 103 ⁄ 4 101 ⁄ 4 1 6 1 2” Minus Product Range: 1” to 2 ⁄ Pinion Speed: 700 to 800 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

1400LS Medium Chamber

Bowl Liner: 540115 All Dimensions in Inches Mantle: 540101 A B C Max. Feed Material 91 ⁄ 2 83 ⁄ 4 11 ⁄ 4 91 ⁄ 8 91 ⁄ 4 81 ⁄ 2 1 87 ⁄ 8 7 91 ⁄ 8 83 ⁄ 8 8 ⁄ 8 3 9 81 ⁄ 4 4 ⁄ 4 Product Range: 5 ⁄ 8” to 1” Minus Pinion Speed: 700 to 850 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

62

C R U S H I N G

1400LS Medium Fine Chamber

Bowl Liner: 540114 All Dimensions in Inches Mantle: 540101 A B C Max. Feed Material 51 ⁄ 2 4 1 43 ⁄ 4 7 1 ⁄ 8 2 51 ⁄ 4 33 ⁄ 4 4 ⁄ 3 ⁄ 4 51 ⁄ 8 35 ⁄ 8 43 ⁄ 8 5 1 ⁄ 8 4 5 31 ⁄ 2 4 ⁄ Product Range: 3 ⁄ 8” to 3 ⁄ 4” Minus Pinion Speed: 750 to 850 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

1400LS Fine Chamber

Bowl Liner: 540274 All Dimensions in Inches Mantle: 540273 A B C Max. Feed Material 3 ⁄ 4 41 ⁄ 8 21 ⁄ 2 31 ⁄ 4 5 ⁄ 8 4 23 ⁄ 8 31 ⁄ 8 1 ⁄ 2 37 ⁄ 8 21 ⁄ 4 3 1 3 ⁄ 8 8 33 ⁄ 4 1 ⁄ 3 Product Range: 3 ⁄ 8” to 5 ⁄ 8” Minus Pinion Speed: 800 to 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio.)

63

C R U S H I N G

B U M H R O T O M

B U M M M M H

M M

0 0 0 . . . 6 9 0 E V 1 1 2 A E V M M V V H 8 8 S 8 0 0 0 1 1 1

R O T O M

5 2 0 5 . . . . 2 3 4 2 E V 1 1 1 1 A E V V V V H 8 8 8 S 8 2 2 2 2 1 1 1 1

0 0 . . 7 8 E ⁄ 1 2 1 2 2 - ⁄ R 1 1 ⁄ 1 V V O 3 3 3 8 8 B 0 1 0 1

E R O B

D E E P S

D E E P S

R O T O M E E L L E G L G N N G I R E I R N S S E E E I V V 2 2 B B H H ⁄ ⁄ A A P S P 1 1 S S U U N N N E E 3 3 H U H H U H H P P P N – H R R S 0 0 C C S A 0 0 3 3 T A – – D R R E O O T T V 8 8 8 0 0 0 8 I O . . . . . . . O 4 4 4 E 0 0 0 4 R M E M V 2 2 2 2 V 3 3 3 D A A N N E V V V M M E V V V V T H 8 8 8 H P P 8 8 8 8 L S S R R 0 0 0 E 2 2 2 2 1 1 1 0 1 1 1 1 0 B 0 0 8 V 2 1 1 S L 0 8 8 . . M M 0 M M M M M 4 4 4 P P P P P P P 2 2 1 R - - R R R R R R N O I N I P

V V 0 0 0 8 8 5 0 5 0 7 0 9 9 1 1

5 5 5 5 2 7 2 7 7 7 8 8

N O I N I P

E E E M N S U I N I F I R / F A D D E E / X O C M M E

E M E S M P P E N R I R R N F A 0 0 I / F O 0 5 C 8 8 X S R E N I L E V A E H S

64

S R E N I L

M U I E D I E N F M / D E M

E V A E H S

E N I F

C

ROLL CRUSHERS APPROXIMATE TWIN AND TRIPLE ROLL CRUSHER GRADATION—OPEN CIRCUIT Test Sieve Sizes (in.)

Roll Crusher Settings 1 ” ⁄ 4

3 ” ⁄ 8

1 ” ⁄ 2

3 ” ⁄ 4

1”

1 ” 1 ⁄ 4

1 ” 1 ⁄ 2

2”

1 ” 2 ⁄ 2

3”

4”

6.35 9.53 12.7 19.0 25.4 31.8 38.1 50.8 63.5 76.2 102 mm mm mm mm mm mm mm mm mm mm mm

Test Sieve Sizes (mm)

8”

Values Shown are

203

6”

Percent Passing

152

5”

R U S H I N G

127

4”

85

102

85

63

75.2

85

70

50

63.5

85

69

54

36

50.8

85

62

50

37

26

38.1

85

70

50

40

31

22

31.8

85

70

52

38

31

25

17

25.4

85

65

50

36

27

24

19

14

19.0

85

60

40

29

24

20

16

14

10

12.7

85

65

40

27

22

19

15

13

11

8

9.53

3” 1 ” 2 ⁄ 2

2” 1 ” 1 ⁄ 2 1 ” 1 ⁄ 4

1” 3 ” ⁄ 4 1 ” ⁄ 2 3 ” ⁄ 8 1 ” ⁄ 4

85

58

41

24

19

16

14

11

9

8

5

6.35

#4

61

39

26

18

15

13

11

9

7

6

4

#4

#8

31

20

16

12

10

8

7

6

5

4

3

#8

#16

16

12

9

7

6

5

4

3

2

2

2

#16

#30

9

7

5

4

3

3

3

2

1

1

1

#30

#50

6

4

3

3

2

2

2

1

0.5

0.5

0.5

#50

#100

4

3

2

2

1

1

1

0.5

0

0

0

#100

Gradation result may be varied to greater fines content by increasing feed and corresponding horsepower.

65

C

ROLL CRUSHERS APPROXIMATE TWIN AND TRIPLE ROLL CRUSHER GRADATION CLOSED CIRCUIT WITH SCREEN

R U S H I N G

Test Sieve Sizes (in.)

Roll Crusher Settings 1 4” ⁄

6.35 mm

3 8” ⁄

1 2” ⁄

3 4” ⁄

1”

1 1 ⁄ 4”

2”

1 2 ⁄ 2”

3”

9.53 12.7 19.0 25.4 31.8 38.1 50.8 63.5 76.2 mm mm mm mm mm mm mm mm mm

4”

Values Shown are

3”

Percent Passing

4” 102 mm 100

102

100

79

76.2

100

91

64

63.5

100

85

75

48

50.8

100

79

63

55

35

38.1

100

90

63

50

44

29

31.8

100

85

75

46

39

34

23

25.4

100

80

66

55

33

28

25

18

19.0

100

75

55

41

33

22

20

18

13

12.7

100

80

55

36

28

24

18

16

14

10

9.53

1 4” 100 ⁄

75

53

33

23

19

18

13

11

10

7

6.35

#4

80

55

35

22

17

15

14

10

9

8

5

#4

#8

40

25

19

14

12

10

9

7

6

5

3

#8

#16

18

14

11

8

7

6

5

4

3

3

2

#16

#30

11

8

6

5

4

4

3

3

2

2

1

#30

#50

7

5

4

3

3

3

2

2

1

1

0.5

#50

#100

4

3

3

2

2

2

1

1

0.5

0.5

0

#100

Roll Setting 80% of

1 2 ⁄ 2”

Screen Mesh Size

2” 1 1 ⁄ 2” 1 1 ⁄ 4”

1” 3 4” ⁄ 1 2” ⁄ 3 8” ⁄

1 1 ⁄ 2”

Test Sieve Sizes (mm)

Gradation result may be varied to greater fines content by increasing feed and corresponding horsepower.

66

C

TWIN ROLL CRUSHERS RECOMMENDED HP Size

Electric

Diesel (Continuous)

50 100 125 200 150 250 300 250 350

75 150 175 300 200 325 400 325 475

**2416 **3018 3024 **3030 **4022 4030 4240 **5424 **5536

R U S H I N G

APPROXIMATE CAPACITIES IN TPH FOR OPEN CIRCUIT (Use 85 percent of these values in closed circuit) Roll Settings 1 4” ⁄

Size

1 2” ⁄

3 4” ⁄

1 1 ⁄ 4”

1”

1 1 ⁄ 2”

2”

1 2 ⁄ 2”

3”

**2416 16 31 47 63 79 94 **3018 25 50 75 100 125 150 200 3024 33 66 100 133 166 200 266 **3030 41 82 125 166 207 276 344 414 **4022 34 69 103 138 172 207 276 344 414 4030 53 106 160 213 266 320 426 532 640 4240 70 141 213 284 354 426 568 709 853 **5424 44 87 131 175 228 262 350 437 525 **5536 65 130 195 261 326 390 522 652 782 *Based on 50% of theoretical ribbon of material of 100# / ft. 3 Bulk Density–capacity may vary as much as ± 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed size. To find Yd.3 /Hr., multiply by .74. For larger settings, consult factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES) Roll Setting 1 ⁄ 4 3 ⁄ 8 1 2 ⁄ 3 ⁄ 4

1

1

1 ⁄ 4 1 1 ⁄ 2 2 1 2 ⁄ 2 3

24” Dia. Rolls

30” Dia. Rolls

1 ⁄ 2 3 ⁄ 4

1 ⁄ 2 3 ⁄ 4

1

1

1

1 ⁄ 2 2 3 2 ⁄ 8 3 2 ⁄ 4

*With smooth shells No beads ** Not current production models

1

1 ⁄ 2 2 3 2 ⁄ 8 3 2 ⁄ 4 1 3 ⁄ 2

40” or 42” Dia. Rolls 5 ⁄ 8

1

1

1 ⁄ 4 7 1 ⁄ 8 1 2 ⁄ 2 7 2 ⁄ 8 1 3 ⁄ 8 3 3 ⁄ 4 3 4 ⁄ 8 5

Bead one shell

54” or 55” Dia. Rolls 3 ⁄ 4 1 1 ⁄ 8 1 1 ⁄ 2 1 2 ⁄ 4

3

3

3 ⁄ 8 3 3 ⁄ 4 1 4 ⁄ 2 1 5 ⁄ 4 6 Bead two shells

67

C

TWIN ROLL CRUSHERS RECOMMENDED HP

R U S H I N G

Size ** 2416 ** 3018 3024 ** 3030 ** 4022 4030 4240 ** 5424 ** 5536

Electric

Diesel (Continuous)

50 100 125 200 150 250 300 250 350

75 150 175 300 200 325 400 325 475

APPROXIMATE CAPACITIES IN MT/H* FOR OPEN CIRCUIT (Use 85 percent of these values in closed circuit) Roll Settings 6.35 12.7 19.0 25.4 31.7 38.1 50.8 63.5 76.2 Size mm mm mm mm mm mm mm mm mm **2416 14 28 43 57 72 85 **3018 23 45 68 91 113 136 181 3024 30 60 91 121 150 181 241 **3030 37 74 113 150 188 227 301 **4022 31 62 93 125 156 188 250 312 375 4030 48 96 145 193 241 290 386 483 580 4240 64 128 193 257 321 386 514 644 773 **5424 40 79 119 159 207 238 317 396 476 **5536 59 118 177 237 296 354 473 591 709 *Based on 50% of theoretical ribbon of material of 1600 kg / m3 Bulk Density–capacity may vary as much as ± 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed size. To find cubic meters per hour, multiply by 1.6. For larger settings, consult factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (MILLIMETERS) Roll Setting 6.35 9.52 12.7 19.0 25.4 31.7 38.1 50.8 63.5 76.2

68

610 mm Dia. Rolls 12.7 19.0 25.4 38.1 50.8 60.3 69.8

762 mm Dia.Rolls 12.7 19.0 25.4 38.1 50.8 60.3 69.8 88.9

1016 mm or 1372 mm or 1066 mm 1397 mm Dia. Rolls Dia. Rolls 15.9 19.0 25.4 28.8 31.7 38.1 47.6 57.1 63.5 76.2 73.0 85.7 79.4 95.2 95.2 114 111 133 127 152

C

TRIPLE ROLL CRUSHERS RECOMMENDED HP Size

Electric

Diesel (Continuous)

125 150 250 200 300 400 300 450

175 200 375 275 400 525 400 600

**3018 3024 **3030 **4022 4030 4240 **5424 **5536

R U S H I N G

APPROXIMATE CAPACITIES IN TPH* FOR OPEN CIRCUIT—SINGLE FEED (Use 85 percent of these values in closed circuit single feed only)

Roll Settings Size

1 4” ⁄

1 2” ⁄

3 4” ⁄

1 4” 1 ⁄

1”

1 2” 1 ⁄

2”

1 2” 2 ⁄

**3018 37 75 112 150 187 225 3024 52 104 156 208 260 312 **3030 65 130 195 260 325 390 **4022 58 117 176 234 292 350 468 584 4030 79 159 238 318 398 476 636 796 4240 105 212 317 424 530 634 848 1061 **5424 65 131 198 262 328 392 524 655 **5536 97 195 293 391 489 586 782 977 *Based on 75% of theoretical ribbon of material of 100# / ft. 3 Bulk Density–capacity may vary as much as ± 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed size. To find Yd.3 / Hr., multiply by .74. For larger settings, consult factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES)

Smaller Setting 1 4 ⁄ 3 ⁄ 8 1 ⁄ 2 3 ⁄ 4

1 1 4 1 ⁄ 1 1 ⁄ 2 2 1 2 2 ⁄

30” Dia. Rolls Larger Max. Setting Feed 1 2 ⁄ 3 ⁄ 4

1 1 2 1 ⁄ 7 1 ⁄ 8 2 2

40” or 42” Dia. Rolls Larger Max. Setting Feed

1 1 2 1 ⁄ 2 3 1 2 3 ⁄ 1 3 ⁄ 2 1 2 3 ⁄


9 15 ⁄ 13 ⁄ 16 1 8 1 ⁄ 11 1 ⁄ 16 1 4 2 ⁄ 1 2 ⁄ 2 3 4 2 ⁄

3 3

1 4 1 ⁄ 7 1 ⁄ 8 7 8 1 ⁄ 3 3 ⁄ 4 5 5 5 5 5

Bead one shell

54” or 55” Dia. Rolls Larger Max Setting Feed 5 8 ⁄ 15 ⁄ 16 15 ⁄ 16 13 1 ⁄ 16 7 16 2 ⁄ 7 2 ⁄ 16

3 3 3

1 1 ⁄ 2 1 2 ⁄ 4 1 2 ⁄ 4 1 4 ⁄ 2 6 6 6 6 6

Bead two shells

69

C

TRIPLE ROLL CRUSHERS RECOMMENDED HP

R U S H I N G

Size

Electric

Diesel (Continuous)

125 150 250 200 300 400 300 450

175 200 375 275 400 525 400 600

**3018 3024 **3030 **4022 4030 4240 **5424 **5536

APPROXIMATE CAPACITIES IN MT/H* FOR OPEN CIRCUIT—SINGLE FEED (Use 85 percent of these values in closed circuit single feed only)

Roll Settings (mm) Size **3018 3024 **3030 **4022 4030 4240 **5424 **5536

6.35

12.7

19.0

25.4

31.7

38.1

50.8

63.5

33 47 59 53 72 96 59 88

68 94 118 106 144 192 119 177

102 141 177 160 216 288 180 266

136 189 236 212 288 384 238 355

170 236 295 265 361 481 297 444

204 283 354 317 432 576 356 532

424 577 769 475 709

530 722 962 594 886

*Based on 75% of theoretical ribbon of material of 1600 kg / m 3 Bulk Density–capacity may vary as much as ± 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed size. To find cu. meters per hour, multiply by 1.6. For larger settings, consult factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (MM)

Smaller Setting 6.35 9.52 12.7 19.0 25.4 31.7 38.1 50.8 63.5

762 mm Dia. Rolls Larger Max. Setting Feed 12.7 25.4 19.0 38.1 25.4 50.8 38.1 76.2 47.6 88.9 50.8 88.9 50.8 88.9

1016 mm or 1066 mm 1372 mm or 1397 mm Dia. Rolls Dia. Rolls Larger Max. Larger Max Setting Feed Setting Feed 14.3 31.7 15.9 38.1 20.6 47.6 23.8 57.1 28.6 63.5 31.7 76.2 42.9 95.2 46.0 114 57.1 127 61.9 152 63.5 127 69.8 152 69.8 127 76.2 152 76.2 127 76.2 152 76.2 127 76.2 152


70

Bead one shell

Bead two shells

C

CAPACITY MULTIPLIERS FOR OPEN CIRCUIT R U TWIN FEED VS. SINGLE FEED S TRIPLE ROLLS H Triple roll twin feed capacities are obtained by selecting a multiplier from the chart (depending on coarse/fine feed ratio) and applying the same to the single feed triple roll capacity. Roll crusher capacities at given settings will vary depending on horsepower available, slippage of feed on shells in crushing chamber, type of shells, and size of feed. Based on a reduction ratio of 2 to 1 in each stage. Feed Split Ratio Coarse/Fine 20/80 30/70 40/60 50/50 60/40 67/33 70/30 80/20 90/10

Capacity Through Crusher .83 .97 1.13 1.35 1.66 2.00 1.95 1.75 1.55

Capacity That is Product Size .73 .77 .85 .95 1.12 1.30 1.24 1.04 .82

(12.7 mm) 1 2” ⁄

EXAMPLE: (4030 Triple Roll)

1”

(25.4 mm)

1 2”—(12.7 mm—) Product = 159 TPH (1) Single feed capacity for ⁄ (144 t/h). (2) Twin feed capacity with “feed split ratio coarse/fine” 67/33 is 159 x 2 = 318 TPH (144 x 2 = 288 mt/h). (3) Single feed open circuit product 159 x .85 = 135 TPH (144 x .85 = 122 mt/h). (4) Twin feed open circuit product is 159 x .85 x 1.3 = 175 TPH (144 x .85 x 1.3 = 159 mt/h).

71

I N G

C

DETAIL DATA FOR ROLL CRUSHER PERFORMANCE (TWIN ROLLS)

R U S H I N G

No. of Teeth Unit

Pinion

Gear

Countershaft RPM

2416 3018 3024

**

15 17 17

68 82 82

270 325 325

346 530 530

**

19

73

300

623

**

4022

18

103

325

600

4030

19

91

310

680

4240 5424

17 19

88 118

320 310

680 700

17

88

250

700

**

3030

**

**

5536

Shell FPM

Rubber Star Gears Tires Working Working Centers, Centers, In. Inches

No. of Springs Per Roll

— 22 1 ⁄ 4-253 ⁄ 4 — 28 1 ⁄ 4-33 30-32 28 1 ⁄ 4-33 (7 x 18) 30-32 — (7 x 18) 39-42 37 1 ⁄ 2-421 ⁄ 2 (10 x 22) 40-43 (11 x 22) 39-42 37 1 ⁄ 2-421 ⁄ 2 (10 x 22) 40-43 (11 x 22) 41-45 — 53-58 53-57 (12 x 36)

2 2 2

53-58 (12 x 36)

—

8 8

8

8 8 8 8 12

DETAIL DATA FOR ROLL CRUSHER PERFORMANCE (TRIPLE ROLLS) No. of Teeth Unit

Pinion

Gear

Countershaft RPM

3018

17

82

325

530

3024

18

82

325

555

**

3030

19

73

300

623

**

4022

19

91

310

680

**

4030

**

**

19

91

680

4240 5424

17 19

88 118

320 310

680 700

5536

17

88

250

700

** Not current production models

72

310

Shell FPM

Rubber Star Gears Tires Working Working Centers, Centers, In. Inches —

281 ⁄ 4-33

30-32 281 ⁄ 4-33 ( 7 x 18) 30-32 — ( 7 x 18) 39-42 371 ⁄ 2-421 ⁄ 2 (10 x 22) 40-43 (11 x 22) 1

1

39-42 37 ⁄ 2-42 ⁄ 2 (10 x 22) 40-43 (11 x 22) 41-45 — 53-58 53-57 (12 x 36)

53-58 (12 x 36)

—

No. of Springs Per Roll 2 2 2 2 8 8 8 8 8 8 12 8 8 8 8 12

C

VERTICAL SHAFT IMPACT CRUSHER

R U S H I N G

Wheel-Mounted

Stationary Plant

Bare Unit 73

C

VERTICAL SHAFT IMPACT CRUSHER R U OPERATION S H I N These Vertical Shaft Impact Crushers are best applied in G tertiary and quaternary applications and various secondary applications. Rock fed to the crusher’s accelerator mechanism (table or rotor) is flung outwards by centrifugal force against the stationary anvils or hybrid rock shelf for free-body impacting. The proper chamber configuration is application dependent. Major crushing advantages include: Precise gradation control; and production of chips and asphalt aggregates fines; compliance with cubical and fracture count specifications, for today’s tight specification requirements such as Superpave.

74

VSI Animation http://youtu.be/-Xn0gnB0y1w

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R U S H I N G

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y r a d n o c e S 76

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, e d o e h s e p 4 s r o m 3 u , m d i x e a e p s m m u % 0 m 0 i 1 x a 0 m 7 e r i % u 0 q 8 e 0 5 r s e n r i i o u t q a e r d a r s g n o i e t s a n d e . a r d e g y l b l e a s a t r c i a e p o o y c h l T s a . 5 c l i e r p b y a o T t 4

R U S H I N G

% 5 0 2 0 0 5 0 0 9 8 6 4 3 1 1 7 5 4 3 0 1

d e e F

l t a u c p i t p u y d T O e

% 8 0 8 0 6 3 4 5 0 0 9 9 7 6 4 3 2 1 1 7 5 4 3 0 1

e F ” 2 d e e H F 2 8 , H 0 l t 0 a u % c t 0 8 4 3 9 2 0 8 0 4 9 6 4 3 2 5 i 2 p p 9 9 8 6 5 4 2 2 1 u 0 , d y O 1 e T H e 0 F 0 5 ” 1 3 d s e l e e F d o M e

z i S m m m m m m m m m m m M M M M m m m m m m m m u u u u e m m m 5 5 m 8 0 0 0 5 v . 5 9 5 . 5 0 7 e m 5 . 3 . 7 y i 2 . 2 1 . 0 0 5 7 7 5 2 1 r S 3 1 9 6 4 1 6 3 1 a e i z s t M S h M M M M e ” ” ” r i ” ” ” M M 0 0 2 ” ” ⁄ 6 0 0 4 2 8 4 ⁄ ⁄ ⁄ ⁄ e 4 8 0 0 3 2 1 1 c 3 1 3 1 e i 1 3 5 v 1 # # 1 2 n # # # e # # T S i

77

- t - r t d e e r o a h a l e i u c p o o d d c a f e r e r x a n i e e u p r p e . a . d b d r g m c r , T t d o e t i d l t L L u s m f a i u e o u e , r A . e l o i s w p e u f f t p t y I A C e t o o i m f l p l n u g u i g R H T k i i c a o o n x o n r a a d b t , e E P E t i s t t l a r d i o T i c h e n a r o t S e , l m n A A T d u s h c f w f e f t e h a s d n d c o M , N e i n i n o s f u a r b i e o n o r e t D E E n c s c i e c a t n u e f % l e e a a a e r u t , e e d 0 a c e M e r E S r a n r l 0 A V c s a t a u e r a g u D B E 1 t r s . u c a o l i v L s a n h i a t i A P n p e d G t g o t n o o n . i s f R R P e n n t t d i g s e e e a u % a r t m o e n G O U b d r , r n o 0 u t o d e r e F f e c d e l o c m E S 5 l v a g e v e a i i C S S a i a e e s i a f a , r l e F f p l n m L N E D i w i h t e a . , s b o o n o r t N n i l d r N n c a n r l a E f I e m e i h i o A o a r t e w e i l D F s a d l t t a o r c a A N S a b a a e v s m d e h i , s d t c a d p a d e e t i l p n G O L s n u , a p z h m r i p r p g i s t g s y a N S A e p g , i d a I n - r l u u t l , e a l n T t I I R f o d o e n e c e i t u l p g e i a o S C S e E l r s g d e i t e n e p A a e m U T a p i n t o F r o e h c a h i r i : u D H A i s m h n h e i g t s p i u O P M p r y m T f o d u e : d g l c r n d u c R M T c s c i n e l t o e c n s c i P E : n n c z u e e a e s i f n i i r d s p c e e c l e e - t e e r e t n f e n r r b u c f e c i e c n i p i o c a F u O r s i d s t t s

C R U S H I N G


d e e F


% 9 0 8 3 2 3 1 5 0 0 9 9 7 6 5 3 2 1 1 6 4 0 1

% 4 5 3 2 9 0 7 8 2 0 9 8 7 6 4 4 2 1 1 8 6 4 0 1

d e e F

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y r a i t r e T 78

i m m m m m M M M M m m m S m m m m m m m m u u u u m m 5 m m 5 m m 5 e 0 0 0 5 m 8 . 5 . 5 3 m v 5 0 9 . . 7 1 0 5 2 7 2 . . e 7 5 3 2 1 1 9 6 4 1 0 6 3 1 7 i S e z s i M S h M M M M e ” ” ” ” ” ” M M 0 2 ” ” ⁄ 4 ⁄ 2 ⁄ 8 ⁄ 4 4 8 6 0 0 0 0 ⁄ 1 1 3 e 3 2 c 1 3 1 3 5 1 0 v 1 # # 1 n # # # # 2 e i # i S

n o n i i t e a n r o u t g s i e f n m o i L C l d a r c a i p d y n a T t S

- d i a n n s M r e a s 4 i # o c s u i n f t i a f n n e o m g i u n t i n o c h i c s a d g r e r l n f a i a e i r n h m g r u e g 0 e e t t e u 0 r c r S a o s c a r 1 r N H f s h n m # t o i s d s d e O , t l I 2 h e e i n e n t a e T 8 e c l f , r f i f e f r l i r o A H o c e o a c n c l C 0 s o e , b I 0 p m o p r i e a t e t L 5 p i s o r r s a f , r n P 2 s o x r f a p 3 . x y a d o o 3 P , i l p a e m e t c a C A H h t m f f e c e e a c f r o E 0 v M - f e h 0 r t o e o T e f Z o I 5 f d k e % f S o 0 o e o m % S 1 e e A r h 0 0 s n m . h c l r z t 8 1 r l D e i e o t t e f u o a s t t h E d n i 0 0 e o t d r e n i 5 8 r h E o d t e l o m e s f e w l i t g % s e e t F e e a a t a d e b o u d 5 l e e e n c a ” M f o 8 e k e b g . m e o t t e a n i o i f d n 1 i p w t d t : : d e s e y p e a s p h o l o d r i r r s i o t t o s c s f e m e m e a u a e r r h e o t r r o h p l ” e o f e s a d o r r e e g f r l e e h g r c q 1 r f h l i e a g l l u s h h r 4 c r p e t h n i g g g e e s s g c n l g r d e a y u p u n n p s a i u u n f A l i a R o o v i l s r i w . a t o m r R t l T l M I m a r u h u I C 3 C F s o u u d n s n w u h i e h s s • • • • • • • • s y i u g r a o e i e S c h u m C m L R H R * e g d * n e M a n 4 % 5 8 4 2 3 0 7 4 3 2 1 9 R e # e 0 r h c t 1 g S a i H e t g u % 7 5 0 2 1 4 5 1 a p r 0 9 8 7 5 4 2 1 1 7 5 3 t e 0 u v 1 O A r e g h s n i e u h s % 0 8 3 2 3 1 5 0 g r g n s 0 9 H C i a 0 9 9 7 6 5 3 2 1 1 6 4 2 . a H 8 x R P 1 , o % H r 0 p 0 p 5 A e 2 % 5 0 2 0 0 5 0 , w g 0 9 8 6 4 3 1 1 6 5 4 3 n o H 0 a L 0 1 R 0 5 1 s l e d d e o e F M

y r a n r e t a u Q

e z i m m m m m M M M M S m m m m m m m u u u u m m 5 e m m m 5 6 8 0 0 0 5 . 5 3 v m 5 9 2 . . 7 0 5 7 . 3 . 1 . 0 e 2 1 1 9 6 4 6 i 2 1 3 1 S e z i S s 0 e ” ” ” ” 4 8 6 0 0 0 0 0 e h ” 4 2 8 4 ⁄ ⁄ ⁄ ⁄ 1 3 5 v c 1 3 1 3 1 # # # # # 1 2 # # e i n i S

79

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C R U S H I N G

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r t y e u t h p i s h c a u p r g u a C o C r h T

: m e z ” d u i e S m b i d u x e a e C M F “

/ - n g h o t i k t e i 0 m d 0 n 6 n o 1 c ( o p l , u a d r t i r a n y e t e c d a i b n m e f u p c e o r d n e o p % i t . 5 a s 2 d b l ± a 0 s r g 0 a ” 2 ” ” ⁄ d 7 , h 2 2 1 n 2 2 c . a s g u s r n m i c o i t t h s s c g a i a i r f e y e r r t w a e v c l h a t a y r i a o r a h e m c d t a s , n a g t e A A A m i n n t i i 0 0 0 n d c 0 0 0 o a a e 5 5 5 p p o m 1 2 4 u a l i p l l l f d u e e e C o e d d d . s q s ) e o o o 3 a d f M M M B m o o H H H P P P T T T 0 0 0 5 0 0 1 - 3 - 5 5 0 0 7 5 0 1 3

% 6 0 6 8 5 7 5 7 3 0 9 9 7 5 4 3 2 1 1 8 5 3 0 1

s u o y n d l l e % e % 9 5 0 0 6 8 1 2 5 1 u g 0 e 0 9 9 9 7 5 3 3 2 1 1 8 6 4 F t o 0 p 0 1 1 S u A A 0 0 5 4 , A 0 0 d 5 ” 2 e ⁄ 2 1 e , 1 F A 0 0 5 1 s l e d o e z M i m m M M m m S m m m m m m m m m m m m M u u u M m m 5 m 8 0 u m 5 m m m e 0 5 0 0 5 . 1 5 9 . 5 3 v m 5 7 . . 7 1 0 0 5 2 . 2 . 7 e i 3 3 2 1 1 9 6 4 1 6 3 1 S

s u o n e g e z i o s S M t e h ” e ” ” M M M ” ” ” M M M 0 0 2 ⁄ 4 ” ” ⁄ 6 0 0 4 2 8 4 ⁄ ⁄ ⁄ ⁄ 1 1 8 1 3 5 0 0 u v c 2 1 1 1 3 1 3 1 4 # # # # # 1 2 e n # # i A i S 80

C

VERTICAL SHAFT IMPACT CRUSHER CRUSHING CHAMBER TERMINOLOGY

R U S H I N G

FULLY AUTOGENOUS ROTOR & HYBRID ROCK SHELF Rock-on-rock crushing; rotor flings rock against bed of rock on outer hybrid rock shelf, and exposed portion of anvils lining the hybrid rock shelf for free-body impacting. Variable reduction ratios of 10:1 to 3:1.

SEMI-AUTOGENOUS ROTOR & ANVIL Crushing chamber has autogenous rotor and standard stationary anvils for specialized crushing and materials problems; 1 2-2” feed sizes and vari1 ⁄ able reduction ratios of 10:1 to 3:1.

STANDARD CONFIGURATION SHOE & ANVIL Impeller shoes in chamber fling rock at true right angles to stationary anvils; rock gradations controlled by impeller table speed. Variable reduction ratios of 10:1 to 3:1.

81

FAST TRAX® SCREEN PLANTS

T

R A C K S

KPI-JCI and Astec Mobile Screens track-mounted screens are engineered to provide higher production capacities and more efficient sizing compared to conventional screens. Featuring triple shaft, oval motion screens, these plants offer better bearing life, more aggressive screening action for reduced plugging and blinding, and a consistent material travel speed that does not accelerate through gravity for a higher probability of separation. As such, these highly efficient plants are perfect for both portable and stationary producers who need quick, effortless on-site movement and reduced down time.

Model

Screen Size (ft / cm)

Decks

Production (tph / mtph)

Weight* (lbs / kg)

FT3620

6 x 20 / 183 x 609

3

700 / 635

81000 / 36741

FT6203OC

6 x 20 / 183 x 609

3

800 / 726

83000 / 37648

FT6203CC

6 x 20 / 183 x 609

3

800 / 726

86000 / 39009

FT710 KDS

7 x 10 / 2134 x 3048

2

200 / 181

35000 / 15876

*These weights should not be used to determine shipping costs. For exact weights, please consult factory personnel or your local KPI-JCI and Astec Mobile Screens dealer.

82

FAST TRAX® HiGH FREQUENCY SCREEN PLANTS

T

R A C K S

Astec Mobile Screens high frequency screens are engineered to provide higher production capacities and more efficient sizing compared to conventional screens. High frequency screens feature aggressive vibration applied directly to the screen that allows for the highest capacity in the market for removal of fine material, as well as chip sizing, dry manufactured sand and more.

Model

Screen Size (ft / cm)

Production (tph / mtph

Weight* (lbs / kg)

FT2618V

6 x 18 / 183 X 547

350 / 318

62000 / 28123

FT2618VM

6 x 18 / 183 x 547

350 / 318

60000 / 27216


83

FAST TRAX® JAW PLANTS

T

R A C K S

KPI-JCI Fast Trax jaw plants are built for maximum jaw crushing mobility. Featuring Vanguard Plus Series Jaw Crushers, these plants are equally effective in aggregate or recycling applications. Both plants allow stationary and portable producers to benefit from the on-site mobility these plants deliver. Model

Crusher (in / mm)

Feeder (in x ft / mm)

Grizzly (ft / cm)

FT2650

26 x 50 / 660 x 1270

50 x 15 / 1270 x 4572

5 / 152 (step deck)

FT3055

30 x 55 / 762 x 1397

50 x 15 / 1270 x 4572

5 / 152

Model


Max Feed (in / mm)

Weight * (lbs / kg)

FT2650

400 / 363

21 / 533

96000 / 43545

FT3055

700 / 635

24 / 610

124000 / 56245


84

FAST TRAX® KODIAK PLUS CONE PLANTS

T

R A C K S Fast Trax cone plants are engineered for maximum cone crushing productivity. Each plant features a Kodiak Plus cone crusher that delivers efficient material sizing, making them perfect for both mobile and stationary producers who need quick, effortless on-site movement.

Model

Crusher

Belt Feeder (in x ft / mm)

Capacity (tph / mtph)

FT300DF+

Kodiak Plus 300

42 x 43 / 1067 x 7010

460 / 417

Model

Max Feed Size (in / mm)

Weight*

FT300DF+

11 / 2794

96000 / 43548


85

FAST TRAX® IMPACTOR PLANTS

T

R A C K S

KPI-JCI Track Mounted impactor plants are engineered for maximum impact crushing versatility. Featuring Andreas Series Impact Crushers, these plants come equipped with our standard Overload Protection System (OPS). Delivering dramatically superior performance with an easily adjustable interface, aggregate producers and recyclers alike will benefit from the availability of open or closed circuit configurations, complete with a screen and recirculating conveyor. Model

Crusher (in / mm)


Grizzly (ft / cm)


Weight* (lbs / kg)

FT4240CC

42 x 40 / 1067 x 1016

40 x 14 / 1016 x 4267

4 / 122 (straight)

325 / 295

94000 / 42638

FT4240OC

42 x 40 / 1067 x 1016

40 x 14 / 1016 x 4267

4 / 122 (straight)

325 / 295

81000 / 36741

FT4250CC

42 x 50 / 1067 x 1270

50 x 15 / 1270 x 4572

5 / 152 (step deck)

400 / 363

112500 / 51029

FT4250OC

42 x 50 / 1067 x 1270

50 x 15 / 1270 x 4572

5 / 152 (step deck)

400 / 363

99000 / 44906

FT5260

52 x 60 / 1321 x 1524

50 x 15 /1270 x 4572

5 /152 (step deck)

750 / 680

112500 / 51029


86

GLOBAL TRACK SCREENING PLANTS

T

R A C K S

GT mobile screening plants feature double- or triple-deck screens for processing sand and gravel, topsoil, slag, crushed stone and recycled materials. They provide easy-to-reach engine controls and grease points for routine service, simple-to-use hydraulic leveling gears, hydraulic plant controls and screen angle adjustment. Tethered track remote control is standard with an optional wireless remote track control available. Model

Hopper Capacity (yd / m)

Screen Size (ft / m)

Power (hp / kw)

GT145

10.5 / 8.03

5 x 14 / 1.52 x 4.27

129 / 96

GT205

10.5 / 8.03

5 x 20 / 1.52 x 6.10

129 / 96

Model


Overs Conveyor (in / mm)

GT145

650 / 540

24 / 610

GT205

650 / 540

30 / 762

87

GLOBAL TRACK DIRECT FEED PLANTS

T

R A C K S

GT direct feed plants provide a rugged, mobile screening tool in a highly portable configuration. They were designed to provide a versatile screening plant that would handle high volumes of material in both scalping and sizing applications. The large loading hopper with a HD variable speed apron pan feeder can withstand heavy loads while metering feed material to the screen to optimize screening production and efficiency.

Model

Belt Feeder (in / mm)

Screen Size (ft / m)

Power (hp / kw)


Overs Conveyor (in / mm)

GT165

54 / 1372

5 x 16 / 1.52 x 4.488

129 / 96

650 / 540

54 / 1372

88

GLOBAL TRACK JAW PLANTS

T

R A C K S

The GT125 is your choice for maximum jaw crushing mobility. Featuring a Vanguard Series Jaw Crusher, the GT125 provides a large feed opening for up to 400 TPH. Equally effective in aggregate or recycle applications, this plant allows stationary and portable producers to benefit from the on-site mobility. Cross-belt magnet, under grizzly side delivery and dust-suppression systems are options available to customize the plant to exact specifications. Model

Crusher (in / mm)


Grizzly (ft / cm)

GT125

26 x 40 / 660 x 1012

40 x 14 / 1016 x 4267

4 / 122 (straight)

Model



Weight * (lbs / kg)

GT125

325 / 295

21 / 533

83000 / 37648


89

GLOBAL TRACK CONE PLANTS

T

R A C K S

Global Track cone plants feature a quarry-duty, state of the art cone crusher design in a highly mobile package. At up to 385 TPH of efficient crushing capacity, they provide the lowest operating cost in their class. They can be deployed quickly for maximum flexibility to economically process small volume jobs and are designed to be as simple to operate and maintain as possible.

Model

Crusher

Belt Feeder (in x ft / mm)


GT200DF

Kodiak 200 Plus

42 x 43 / 1067 x 7010

385 / 347

GT200CC

Kodiak 200 Plus

42 x 43 / 1067 x 7010

385 / 347

Model


Weight* (lbs / kg)

GT200DF

9 / 228.6

80000 / 32290

GT200CC

9 / 228.6

103000 / 46720


90

GLOBAL TRACK CONVEYOR

T

R A C K S

The GT3660 is a self-contained, track-mounted, mobile conveyor that can be used as a transfer or stacking conveyor with portable or track crushing and screening equipment. Capable of carrying loads of up to 750 tons per hour with adjustable speed and discharge height, the GT3660 is a perfect tool when quick set-up, mobility and flexibility are required.

Model

Belt Width (in / mm)

Belt Length (ft / m)

Diesel Power (hp / kw)

GT3660

36 / 900

60 / 18.25

60 / 45

Model


Discharge Height (ft/ m)

GT3660

750 / 675

24 / 7.315

91

WASHING INTRODUCTION Clean aggregates are important to the construction industry. Yet producers of aggregates frequently are hard-pressed to meet all requirements for “cleanliness.” Materials engineers constantly strive to improve concrete and bituminous mixes and road bases. While hydraulic methods are the most satisfactory for cleaning aggregates to achieve the desired result, they are not always perfect. It is still necessary to accept materials on the basis of some allowable percent of deleterious matter. In the broadest terms, construction aggregates are W washed to make them meet specifications. Specifically, A however, there is more to the function of water in pro S cessing aggregates than mere washing. Among these H I N functions are: G 1. Removal of clay and silt / C 2. Removal of shale, coal, soft stone, roots, twigs L and other trash A 3. Sizing S S 4. Classifying or separating I F 5. Dewatering Y I N Because no washing method can be relied upon to be G perfect, and because some materials may require too much time, equipment and water to make them conform to specifications, it is not always economically practical to use such materials. It is important, therefore, to test the source thoroughly beforehand to ensure the desired finished aggregates can be produced at reasonable cost. The project materials engineer can be of immeasurable help in determining the economic suitability of the material, and generally must approve the source before production begins, anyway. Further, many manufacturers of washing equipment will examine and test samples to determine whether their equipment can do the job satisfactorily. No reputable equipment manufacturer wants to recommend his equipment where he has a reasonable doubt about its satisfactory performance on the job.

92

The ideal gradation is seldom, if ever, met in naturally occurring deposits. Yet the quality and control of these gradations is absolutely essential to the workability and durability of the end use. Gradation, however, is a characteristic which can be changed or improved with simple processes and is the usual objective of aggregate preparation plants. Crushing, screening and blending are methods used to affect the gradations of aggregates. However, even following these processes, the material may still require washing to meet specification as to cleanliness. Also, screening is impractical smaller than No. 8 mesh and hence, hydraulic separation, or classifying, becomes an important operation.

W

A Washing and classifying of aggregates can be considered S H in two parts, depending on the size range of material. I N Coarse material - generally above 3/8” (sometimes split G / at 1/4” or 4 mesh). In the washing process, it usually is C desired to remove foreign, objectionable material, includ- L A ing the finer particles. S S Fine aggregates - from 3/8” down. In this case, it gener- I F ally is necessary to remove dirt and silt while retaining Y I N sand down to 100 mesh, or even 200 mesh. G

93

GRADATION OF AGGREGATES This term is used to denote the distribution of sizes of the particles of aggregates. It is represented by a series of percentages by weight of particles passing one size of sieve but retained by a smaller size. The distribution is determined by a mechanical analysis performed by shaking the aggregate through a series of nested sieves or screens, in descending order of size of openings. Round openings are used for larger screens, square ones for the smaller sieves. Prescribed methods and prescribed openings of the screens and sieves have been established by the ASTM (American Society for Testing Materials). The nor1 3 3 2”, ⁄ 4”, ⁄ 8”, Numbers mal series of screens and sieves is: 1 ⁄ W 4, 8, 16, 30, 50, 100, 200 mesh. A S SIEVES FOR TESTING PURPOSES H I Screen or Sieve Nominal Opening Equivalents N G Designation mm inches microns 4” 3” 2” 1 1 ⁄ 2” 1” 3 ⁄ 4” 1 ⁄ 2” 3 ⁄ 8” 1 ⁄ 4” No.4 6 8 12 16 20 30 40 50 70 100 140 150 200 270 400

/ C L A S S I F Y I N G

94

101.6 76.2 50.8 38.1 25.4 19.1 12.7 9.52 6.35 4.76 3.36 2.38 1.68 1.19 0.84 0.59 0.42 0.297 0.210 0.149 0.105 0.100 0.074 0.053 0.037

0.187 0.132 0.0937 0.0661 0.0469 0.0331 0.0232 0.0165 0.0117 0.0083 0.0059 0.0041 0.0039 0.0029 0.0021 0.0015

4760 3360 2380 1680 1190 840 590 420 297 210 149 105 100 74 53 37

) m 6 1 m . 8 o . N 1 1 ( ) m 8 m . 6 o N 3 . 2 ( ) m 4 m . o 5 N 7 . 4 ( ) . n m i m 8 5 t ⁄ 3 . n 9 e ( c r e ) P t m . h n m g i i e ⁄ 2 5 . 1 2 W 1 , ( ) s g ) n i n . m e n m p i 0 4 O ⁄ . - 3 9 e r 1 ( a u q ) S ( . m e m n v i e 0 i . 5 S 1 2 y ( r o t ) a r . o i n m m b 2 a ⁄ 5 . L 1 1 7 h 3 c ( a E n ) a h . t n m r i m e 2 0 n i 5 F ( s t n u o n ) i m m ⁄ 2 m A 1 3 2 6 (

S E T A G E R G G A E S R A O C R O F S T N E M E R I U Q E R G N I D A R G

5 0

5 0

5 0

5 1 0 5 1 0

0 7 5 3

0 6 5 2

0 0 1 0 9

0 7 5 3

5 5 0 2 0 0 1 0 9

5 1 5 0 7 1 - - 5 0 0 3 0 7 5 3

0 5 3 - 5 - 1 0 1 0 0

0 3 0 1

5 - 5 0 0

0 0 5 0 5 5 1 1 1 - - - - - 3 0 0 0 0 0 0 1

5 0 5 0

) . n m i m 3 5 7 ( . ) n i m 2 m ⁄ 1 3 0 9 (

0 5 - 5 - 1 0 0 0

5 0

5 1 0 0 6 5 2

5 5 0 2

0 7 0 4

0 0 1 5 8

0 0 0 1 - 0 1 0 9

0 1 0

0 4 0 1

5 5 0 2

5 5 0 2

5 8 0 4

0 0 1 0 9

0 0 1 0 9

0 0 1 0 9

0 0 0 0 1 - 0 1 0 1 5 9

0 0 0 1 - 0 1 0 9

W

A S H I N G

/ C

0 0 0 0 0 1 0 - 0 1 1 0 1 5 9

L A S S I F Y I N G

0 0 0 0 1 - 0 1 0 1 5 9

0 0 0 0 1 - 0 1 0 1 0 9 0 0 1

0 0 1 0 9

) . m n m 0 i 0 0 4 0 1 1 ( ) ) ) ) ) ) ) ) ) ) ) ) ) ) s m m m m 4 m m 4 m 4 m 8 m g . m n . m m 4 m . m 4 e h n . . m . m . m . m t n . m . m o . m z i . . m i i n i i m ⁄ m i m o n 0 o m i n o 5 o 5 o 6 n n i n 5 5 5 2 2 i i ⁄ S w . . 5 5 5 0 5 N 4 e 1 . 1 ⁄ N 8 5 7 7 . 7 7 ⁄ . . N 2 2 ⁄ 8 . N l 3 9 . . . N . N 3 ⁄ 3 7 p s 1 1 1 9 . 1 1 3 9 o o 7 o 3 7 o 2 5 o . a e O o 3 o o o 1 4 4 4 4 t o 2 t t t t o 4 t t o o o o v t m t t t o o o o o o . . . t t t t . n t t r 2 t i e e t ⁄ t i o n o ⁄ 2 o 2 o n 0 n t n o r t n 0 ⁄ 4 0 i i o i 0 1 i 1 t ⁄ 1 t 2 t i t 1 2 5 1 3 a ⁄ 5 0 . . 5 S 1 1 4 2 8 . . . . . . 2 ⁄ ⁄ ⁄ N ( u 3 0 3 0 0 2 5 9 . 1 3 9 1 2 3 5 7 1 3 7 2 5 2 5 1 9 6 5 ( 5 3 q 9 ( ( ( 2 1 1 ( ( ( S ( ( ( ( ( ( r e e b 7 7 5 6 7 6 7 7 8 z i 1 2 3 3 5 4 6 5 5 6 4 S m u N

95

SAND SPECIFICATIONS Common sand specifications are ASTM C-33 for concrete sand and ASTM C-144 for mason sand. These specifications are often written numerically and also shown graphically.

ASTM C-33 Limits % Passing 100 95-100 80-100

Center Spec % Passing 100 97.5 90

16

50-85

67.5

30

25-60

42.5

50

5-30

17.5

100

0-10

5

200

0-3

1.5

Sieve 3 8” ⁄

No. 4 8

W

A S H I N G


ASTM C-144 Limits % Passing 100 100 95-100

Center Spec % Passing 100 100 97.5

16

70-100

85

30

40-75

57.5

50

10-35

22.5

100

2-15

8.5

200

0-10

5

Sieve 3 8” ⁄

No. 4 8

96

PERCENT PASSING 0

0 1

0 2

0 3

0 4

0 5

0 6

0 7

0 8

0 9

0 0 1 0 9 0 5 2 2 7 0 0 . 0 6 1 4 4 0 0 1 1 0 .

9 0 0 5 0 5 0 1 1 0 . 0 7 0 0 0 8 8 1 0 . 3 8 0 2 0 7 1 2 0 . 7 1 0 0 0 1 5 3 0 .

5 6 0 5 2 4 4 1 0 .

4 3 0 0 0 3 6 2 0 .

3 3 C M T S A

0 2

1 3 3 0 .

8 9 6 1 6 1 . 4 1 0 .

6 2 7 . 6 1 1 0 . 8 0 0 . 7 1 2 0 . 6 7 3 8 3 . 9 2 0 .

5 2 3 6 3 . 1 . 3 0 5 7 8 4 7 . 1 . 4 0 0 4 3 / . 5 1 6 2 . 0

0 0 1

0 9

0 8

0 7

0 6

0 5

0 4

G N I S S A P T N E C R E P

0 3

0 2

0 1

5 8 5 / . 7 3 9 3 . 0 0 . L S . M A U M M I C E D

97

W

A S H I N G


PERCENT PASSING 0

0 1

0 2

0 3

0 4

0 5

0 6

0 7

0 8

0 9

0 0 1

0 5 9 0 7 2 2 0 0 . 1 0 6 4 4 0 0 1 1 0 .

9 0 0 5 0 5 0 1 1 0 . 0 7 0 0 0 8 8 1 0 . 3 8 0 2 0 7 1 2 0 . 7 1 0 0 1 5 0 3 0 .

W

A S H I N G

5 6 0 5 2 4 4 1 0 .

/ 4 C 4 L 1 A S C S M I F T Y S I N A

4 3 0 0 0 3 6 2 0 .

M 1 0 µ 3 2 0 3 5 0 . 8

G

8 9 6 1 6 1 . 4 1 0 .

6 2 7 . 6 1 1 0 . 8 0 0 . 1 2 7 0 . 6 7 3 8 3 . 9 2 0 .

5 2 3 6 3 . 1 . 3 0

0 0 1

98

0 9

0 8

0 7

0 6

0 5

0 4

G N I S S A P T N E C R E P

0 3

0 2

0 1

5 7 8 4 7 . 1 . 0 4 0 . M L S . A U M M I C E D

FM AND SE The factor called Fineness Modulus (FM), which is commonly used, serves as a quick check that a given sample meets specifications without checking each sieve size of material against the standards set for a particular job. FM is determined by adding the cumulative retained percentages of sieve sizes #4, 8, 16, 30, 50 and 100 and dividing the sum by 100. Sieve

% Passing

% Retained

#4

97

3

#8

81

19

#16

59

41

#30

36

W

64

#50

15

85

#100

4

96

A S H I N G

308 / 100 = 3.08 (FM)

/ C

Different agencies will require different limits on the FM. L A Normally, the FM must be between 2.3 and 3.1 for ASTM S C-33 concrete sand with only 0.1 variation for all the S I F material used throughout a certain project. Y I The Sand Equivalent Test (SE) is more complex than N G the FM test. The “equivalent” refers to the equivalent quantities of fine versus coarse particles in a given sand sample. The test is performed by selecting a given quantity of a sand sample and mixing it in a special solution. The chemicals in the solution contain excellent wetting agents. These wetting agents will rapidly dissolve any deposits of semi-insoluble clays or plastic clays, which are clinging to the individual sand particles. After a specified period of agitation, either by hand or by machine, the sample is allowed to stand in a graduated tube for a specified time period. A weighted plunger is slowly lowered into the settled sand-solution mixture, and the depth to which the weight descends is noted from the graduations on the tube. A formula is supplied with the testing apparatus, and from that formula the “SE” is determined.

99

In general, the finer the sand, the deeper the weight will penetrate. The wetting agents that dissolve the clay make a seemingly coarse material much finer because the clays are now a separate, very fine product. This extra fine material acts as a lubricant and the weight will descend deeper in the sample. Because of this, it is possible that a sample with an acceptable FM is rejected for failure to pass the SE test.

COARSE MATERIAL WASHING In order to produce aggregate at the most economical cost, it is important to remove, as soon as possible, W from the flow of material, any size fraction that can be A considered ready for use. The basic process consists of S crushing oversize material, scrubbing or washing coatH ings or entrapped materials, sorting and dewatering. I N Beneficiation of some coarse aggregate fractions may G be necessary. When scrubbing or washing of coarse / C material is required, it is generally a consideration of the L material size, the type of dirt, clay or foreign material to A S be scrubbed and the tons-per-hour rate needed that will S determine the coarse material washing equipment to use. I F Y I N G

100

LOG WASHERS

W

A Purpose: In the aggregate business, the log washer is S known best for its ability to remove tough, plastic soluble H N clays from natural and crushed gravel, crushed stone I and ore feeds. The log washer will also remove coatings G / C from individual particles, break up agglomerations, and reduce some soft, unsound fractions by a form of dif- L A ferential grinding. S S F Design: The log washer consists of a trough or tank of I all welded construction set at an incline (typically 6-10°) Y I N to decrease the transport effect of the paddles and to G increase the mass weight against the paddles. Each “log” or shaft (two per unit) is fitted with four rows of paddles which are staggered and timed to allow the paddles of each shaft to overlap and mesh with the paddles of the other shaft. The paddles are pitched to convey the material up the incline of the trough to the discharge end.

101

W

A S H I N G


KPI-JCI and Astec Mobile Screens’ log washer design improves on the traditional design in that the paddles are set in a spiral pattern around the shaft instead of in a straight line as in competitive units. This design feature provides many benefits, including: 1) Reduces intermittent shock loading of the log, 2) Keeps a portion of the mass in motion at all times, thus reducing power peaks and valleys as well as overall power requirements, 3) Reduces wear and 4) Provides more effective scrubbing. Other important features of the log washer include two large tank drain/clean-out ports, rising current inlet, overflow ports on each side of the unit, cast ni-hard paddles with corrugated faces, readily-available externally mounted lower end bearings and a custom-designed and manufactured single-input dual-output gear reducer. Application: The majority of the scrubbing action performed by the log washer is accomplished by the abrading action of one stone particle on another, not by the action of the paddles on the material. Due to this and other feed material characteristics such as clay solubility, the capacity of a log washer is given in a fairly wide range. Normal practice is to follow the log washer with a screening device on which spray bars are used to remove fines and clay coatings on the stone.

LOG WASHERS Model

Capacity (TPH)

Motor (HP)

Water Req’d. (GPM)

8024-18

25-80

40

25-250

3”

12,500

15,000

8036-30

85-200

100

50-500

4”

34,000

45,000

8048-30

125-300

150

100-800

5”

47,500

70,000

8048-35

125-400

200

100-800

5”

53,000

83,000

102

Maximum Feed Size (in.)

Approx. Dead Load (lbs.)

Approx. Live Load (lbs.)

COARSE MATERIAL WASHERS

W

A S H I N G


Purpose: The coarse material washer is used to remove a limited amount of deleterious material from a coarse aggregate. This deleterious material includes shale, wood, coal, dirt, trash and some very soluble clay. A coarse material washer is often used as final 1 3 wash for coarse material (typically -2 ⁄ 2” x + ⁄ 8”) following a wet screen. Both single and double spiral units are available depending on the capacity required. Design: The coarse material washer consists of a long vertical sided trough or tank of all welded construction set at a 15° incline. The shaft(s) or spiral(s) of a coarse material washer begin with one double pitch spiral flight with replaceable ni-hard outer wear shoes and AR steel inner wear shoes. Following this single flight is a variable number of bolt-on paddle assemblies. Standard units include four sets of paddle arms with ni-hard tips. Two sets of arms replace one full spiral. The balance of the spiral(s) consists of double pitch spiral flights with replaceable ni-hard outer wear shoes and AR steel inner wear shoes. 103

Other important features of the coarse material washer include a rising current manifold, adjustable full width overflow weirs, readily-available, externally-mounted lower end bearing(s) and upper end bearing(s) and shaft mounted gear reducer with v-belt drive assembly (one drive assembly per spiral).

W

A S H I N G

Application: As previously noted, the number of paddle assemblies can be varied. The number of paddle assemblies installed on a particular unit is dependent on the amount of water turbulence and scrubbing action required to suitably clean the feed material. As the number of paddles is increased, the operational characteristics of the unit change, including increased scrubbing action, increased retention time, reduced capacity and increased power requirements.


COARSE MATERIAL WASHERS

Model

Capacity (TPH)

Motor (HP)

Water Required (GPM)

Max Feed Size (in.)

Approx. Dead Load (LBS)

Approx. Live Load (LBS)

300-400 400-600 500-700

2½” 2½” 3”

6,200 10,400 15,600

9,000 19,000 38,500

700-900 800-1000

2½” 3”

17,000 28,500

37,000 78,000

SINGLE SPIRAL CONFIGURATIONS. 6024-15S 6036-19S 6048-23S

60-75 150-175 200-250

15 25 40

TWIN SPIRAL CONFIGURATIONS. 6036-19T 6048-23T

300-350 400-500

25 40

NOTE: Two motors required on twin units. 24” diameter unit offered only in single spiral configuration.

104

BLADEMILLS

W

A Purpose: Similar in design to the Series 6000 Coarse S Material Washer, the blademill is used to pre-condition H I aggregates for more efficient wet screening. Blademi- N G lls are generally used prior to a screening and washing / application to break up small amounts of soluble mud C L 1 2” x 0”. Units and clay. Typical feed to a blademill is 2 ⁄ A are available in both single- and double-spiral designs, S S depending on the capacity required. I F Y Design: The blademill consists of a long vertical sided I N trough or tank of all welded construction set at a variable G incline (typically 0-4°), depending on the degree of scrubbing or pre-conditioning required. The shaft(s) or spiral(s) of a blademill begin with one double pitch spiral flight with replaceable ni-hard outer wear shoes and AR steel inner wear shoes. Following this single flight is a combination of bolt-on paddle and flight assemblies, which whi ch can be varied, depending on the amount of scrubbing required. The flight assemblies include replaceable ni-hard outer wear shoes and AR steel inner wear shoes. The paddle assemblies are fitted with replaceable cast ni-hard paddle tips. Other important features of the blademill include readily-available, externally-mounted lower end bearing(s) and upper end bearing(s) and shaft mounted gear reducer with v-belt drive assembly (one drive assembly per spiral).

105

Application: The number of paddle and flight assemblies, as well as the angle of operation, can be varied dependent upon the amount of scrubbing or pre-conditioning required. As the number of paddles or angle of operation is increased, the operational characteristics of the unit change, including increased scrubbing action, increased retention time, reduced capacity and increased power requirements. Capacities/Specifications: Blademill capacity is indirectly a function of retention time. Each application will indicate a required period of time for effective washing, which actually determines the capacity of the unit. As a rule of thumb, a blademill can be expected to process W in the range of a coarse material washer with respect to 1 A raking capacity in TPH and requires approximately ⁄ 4 to 1 S ⁄ 3 of the water required in a coarse material washer. If H sufficient information is not available with regards to clay I N G content and solubility, the lower end of the coarse mateBlademill s are offered / rial washer range should be used. Blademills C L in single or twin screw configurations of the same size as A coarse material washers. S S I F Y BLADEMILLS I N Max Approx. Approx. G Model

Capacity (TPH)

Motor (HP)

Water Required (GPM)

Feed Size (in.)

Dead Load (LBS)

Live Load (LBS)

75-150 100-200 125-250

2½” 2½” 3”

6,900 9,800 17,700

7,500 15,800 30,700

175-350 200-400

2½” 3”

17,200 31,100

28,300 57,600

SINGLE SPIRAL CONFIGURATIONS. 6524-15S 6536-19S 6548-23S

60-75 150-175 200-250

15 25 40

TWIN SPIRAL CONFIGURATIONS. 6536-19T 6548-23T

300-350 400-500

25 40

NOTE: Two motors required on on twin units. 24” diameter unit offered only in single spiral configuration.

106

FINE MATERIAL WASHING AND CLASSIFYING INTRODUCTION Aside from washing sand to remove dirt and silt, hydraulic methods are employed to size the material and to classify or separate it into the proper particle designation. After these steps, it is usual procedure to dewater the product. Washing aggregates to clean them is not new. However, much closer attention has been given to both the cleanliness and the gradation of the fines in construc- W tion aggregates. This has developed a new “art” in the A processing of fine aggregates. This “art” requires more S technical know-how and methods more precise than H I N those usually associated with the mere washing of gravel G and rock. At the same time, it has been necessary to / C advance the art in a practical way so as to produce matemate - L rial at a reasonable price. A S Screening is the best way to separate coarse aggregates aggregat es S I into size ranges. With fine materials, however, screen- F Y ing on less than No. 8 mesh usually is impractical. This I N 3 necessitates a split between ⁄ 8” and #4 mesh putting G everything finer into the category of requiring hydraulic separation for best gradation control. With hydraulic separation, a large amount of water is used. Here, separation depends on the relative buoyancies of the grain particles and on their settling rates under specific conditions of water flow and turbulence. In some cases, separation depends on the relative specific gravity difference between the materials to be separated and the hydraulic medium. In a certain sense, this applies when water is used to separate particle sizes of sands. Perhaps it would be more apt to say this separation of sands is based on relative densities or that the process separates by gravity.

107

In its strictest sense, however, classifying means that several sizes of sand products of equal specific gravity can be separated while rejecting slimes, silt and similar deleterious substances. But sand particles are not necessarily always of the same specific gravity, so frequently both specific gravity and particle size affect the rate of settling. Consequently, you cannot always estimate the probable gradation of the final products without preliminary tests on the material. Nor can you be sure of product quality without analysis and tests after processing.

W

In any hydraulic classification of sand, the amount of fines retained with the final product will be dependent upon: 1. Area of settling basin 2. Amount of water used 3. Extent of turbulence in settling area

A S H I N G

Obviously, the area of the settling basin generally will be L fixed. Hence, the amount and size of fines to be rejected A will be determined by regulating the water quantity and S turbulence. S I F Y I N G

/ C

108

FINE MATERIAL WASHERS

W

A S H I N Purpose: Fine material washers, also frequently called G / screw classifiers or screw dehydrators, are utilized to C 3 L 8” or -#4 clean and dewater fine aggregates (typically – ⁄ A mesh), fine-tune end products to meet specifications and S to separate out slimes, dirt and fines (typically -#100 mesh S I or finer). Available in both single and twin configurations, F Y fine material washers are most often used after a sand I N classifying/blending tank or after a wet screening opera- G tion. Design: The fine material washer consists of an allwelded tub set at an incline of approximately 18.5° (4:12 slope) and includes a full-length curved bottom with integral rising current manifold designed to control fines retention and the water velocity within the pool. The lower end of the tub or tank is flared to provide a large undisturbed pool, which provides accurate material classification. Long adjustable weirs around the top of the sides and end of the tub’s flared portion are designed to handle large volumes of slurry and to control the pool level for uniform overflow. Also incorporated into the design of the tub is a chase water line to clear the drain trough for better dewatering and an overflow flume.

109

The shaft(s) or spiral(s) of the fine material washer consist of a double pitch, solid flight spiral, complete with AR steel inner wear shoes and urethane outer wear shoes, to provide protection of the entire flight (cast ni-hard outer wear shoes are optional). Other important features of the fine material washer include readily-available, externallymounted lower end bearing(s) and upper end bearing(s), shaft mounted gear reducer with v-belt drive assembly (one drive assembly per spiral), and center feed box with internal and external baffles to reduce the velocity of the material entering the fine material washer, and reduce pool turbulence, enhancing fines retention.

Application:

W

A S H I N G


Two important elements must be considered when sizing a fine material washer for a particular application: 1) Calculation of overflow capacities and 2) Calculation of sand raking capacity. Overflow capacity is critical to ensure that the unit has sufficient capacity to handle the water required for proper dilution of the feed material, which allows for proper settling to occur and to produce the desired split point. The requirements for water in a fine material washer are to have approximately 5 GPM of water for every 1 STPH of total sand feed or 50 GPM of water for every 1STPH of silt (-#200 mesh). The larger of these two figures and the desired mesh split to be produced within the fine material washer are then used to assist in sizing of the unit. This process allows for proper dilution of the sand so that the material will correctly settle in the tub. The raking capacity of a fine material washer is governed by the fineness of the material to be dewatered. Generally speaking, the finer the material to be raked, the slower the spiral speed must be, to ensure adequate dewatering and reduced pool turbulence. The following tables are provided to assist in the proper selection of a fine material washer. PERCENT SCREW SPEED vs. PERCENT FINES (in the product) % SCREW SPEED (RPM)

100% 75% 50% 25% 110

% PASSING 50 MESH

% PASSING 100 MESH

% PASSING 200 MESH

15 20 30 50

2 5 10 25

0 0 3 8

FINE MATERIAL WASHERS RAKING & OVERFLOW CAPACITY TABLE

MODEL *5024-25

*5030-25

5036-25

5044-32

5048-32

5054-34

5060-35

5066-35

5072-38

CAPACITY SINGLE/ TWIN (TPH)

MINIMUM OVERFLOW CAPACITIES MOTOR HP (GPM) REQ’D/ SINGLE/TWIN SPIRAL 100 MESH 150 MESH 200 MESH

SPIRAL SPEED %

SPIRAL SPEED (RPM)

50

100%

32

7.5

37

75%

24

5

25

50%

16

5

12

25%

8

3

75

100%

25

10

55

75%

19

10

38

50%

13

7.5

18

25%

7

5

100/200

100%

21

15

75/150

75%

15

10

50/100

50%

12

7.5

25/50

25%

6

5

175/350

100%

17

20

130/260

75%

13

15

85/170

50%

9

10

45/90

25%

5

7.5

200/400

100%

16

20

150/300

75%

12

15

100/200

50%

8

10

50/100

25%

4

7.5

250/500

100%

14

30

185/370

75%

11

25

125/250

50%

7

15

60/120

25%

4

10

325/650

100%

13

30

250/500

75%

9

25

165/330

50%

5

20

85/170

25%

3

15

400/800

100%

11

40

300/600

75%

8

30

200/400

50%

5

25

100/200

25%

3

15

475/950

100%

11

60

355/710

75%

8

50

235/475

50%

5

30

120/240

25%

3

15

500

225

125

550

275

150

700/1200

325/600

175/300

1500/2700

750/1300

400/750

1650/2900

825/1450

450/825

1800/3200

900/1600

525/900

2200/3600 1000/1800

550/950

W

A S H I N G


2400/4000 1100/2000 625/1000

2600/4400 1250/2200 700/1200

NOTE: Two motors required on twin units. *24” & 30” dia. units offered only in single spiral configuration.

111

CLASSIFICATION METHODS APPLIED TO FINE AGGREGATES INTRODUCTION Classification is the sizing of solid particles by means of settling. In classification, the settling is controlled so that the very fines, silts and clays will flow away with a stream of the water or liquid, while the coarse particles accumulate in a settled mass. Washing/classifying equipment is manufactured in many different configurations depending on the natural material characteristics and the end product(s) desired. Although the general definition of aggregate classify- W 3 A ing can be applied to coarse material (+ ⁄ 8”), it is most S 3 8”. Included commonly applied to the material passing ⁄ H in the fine material classifying equipment are the sand I N screws, counter-current classifiers, sand drags and rakes, G / hydro-cyclones, hydro-classifiers, bowl classifiers, hydro- C separators, density separators, and scalping/classifying L A tanks. S S All the above-mentioned classifiers, except the scalping/ I F classifying tank, are generally single product machines Y N which can only affect the gradation of the end product I on the very fine side (the overflow separation size). This G separation size, due to the mechanical means employed, is never a knife-edge separation. However, the aim of modern classification methods is to approach a clean-cut differentiation. Many material specifications today call for multiple sizing of sand with provisions for blending back to obtain the gradations required. It is rare to find the exact blend occurring naturally or to economically manufacture the blend to exact specifications. In either case, the accepted procedure is to screen out the fine material from which the sand specifications will be obtained. This material is processed in a water scalping/classifying tank for multiple separation by grain sizes or particle specific gravity. There is no mystery connected with classifying tanks. They are merely long settling basins capable of holding large quantities of water. The water and sand mix 113

(slurry) is introduced into the tank at the feed end. The slurry, which often comes from dredging or wet screening operations, flows toward the overflow end, and as it does, solids settle to the bottom of the tank. Weight differences between sand particles allow coarser material to settle first while lighter material progressively settles out further along the tank length.

PRINCIPLES OF SETTLING The specific gravity of aggregates varies according to the nature of the minerals in the rock. “Bulk” specific gravity is used in aggregate processing and indicates the relative weight of the rock or sand, including the natural W pores, voids and cavities, as compared to water (speA cific gravity = 1.0). In the case of fine aggregates, the S specific gravity is about 2.65. As a consequence, the H weight of grains of sand will be directly proportional to I N G their volume. All grains of sand of a given size will there/ fore weigh the same, and the weight can be measured in C L relation to the opening of the sizing sieve. A S A second basic consideration is that of the density or S specific gravity of the slurry itself. Dilution is usually I F expressed in percentages by weight of either the solid Y I N or of the water. Since the specific gravity of water is 1.00 G and that of sand is assumed to be 2.65, a simple calculation will give the specific gravity, or density, of the slurry mixture.

CALCULATION OF SLURRY OR PULP The following method of calculating slurry or pulp is quick, accurate and requires no reference tables. It may be used for any liquid-solid mixture. Basic equation, for a single substance or mixture: 4 GPM = TPH x SG For Water: GPM Water = TPH Water x 4 4 For Solids: GPM Solids = TPH Solids x SG Solids 114

For Solids SG 2.65-2.70 (sand, gravel, quartz, limestone): GPM Solids = TPH Solids x 1.5 4 For Slurry: GPM Slurry = TPH Slurry x SG Slurry To solve for Specific Gravity: TPH Slurry x 4 SG Slurry = GPM Slurry Example: Given: 10 TPH of Sand @ 40% Solids (by weight) Find: GPM and SG of Slurry Use this matrix to calculate your data % Weight

TPH

Water

SG

GPM

W

1.0

Solids

40

Slurry

100

10

A S H I N G

2.67

/ C

Fill in as follows: 1) Convert % Weight to decimel form: 40% = 0.40 2) TPH Slurry = TPH solids divided by 0.40 = 25 3) TPH Water = TPH Slurry - TPH Solids = 15 4) GPM Water = TPH Water x 4 = 60 5) GPM Solids = TPH Solids x 1.5 = 15 6) GPM Slurry = GPM Water + GPM Solids = 75 7) SG Slurry = TPH Slurry x 4/GPM Slurry = 1.33 % Weight

TPH

SG

GPM

Water

60

15

1.0

60

Solids

40

10

2.67

15

Slurry

100

25

1.33

75

L A S S I F Y I N G

The tablulation can be solved for all unknowns if SG Solids and two other principal quantities are given. If GPM Slurry, % Solids and SG Solids are given, solve for 1 TPH and divide total t otal GPM Slurry by resultant GPM Slurry to obtain TPH Solids. Rework tabulation with this figure to check the result. Percent Solids by Volume may be calculated directly from GPM column. 115

GPM column may also be extended to any other unit desired; e.g., cubic feet per second. NOTE: 1) The equation is based on U.S. Gallon and std. (short) ton of 2,000 lbs. 2) The difference in result result by using 2.65 or 2.70 SG Solids is negligible compared to the inaccuracy usually inherent in given quantities. 3) For sea water, use SG 1.026. In this case, case, the difference is appreciable. CONVERSION FACTORS To Obtain TPH Short TPH Short TPH U.S. GPM U.S. GPM U.S. GPM

W

A S H I N G


Multiply Cu. Yd/Hr. Long TPH Metric TPH British GPM Cu. Ft./Min. Cu. Ft./Sec.

By 1.35 1.12 1.1023 1.201 7.48 448.5

Based On Sand 100#/cu. 100#/cu. ft., dry. 2240 lb. ton Kilo = 2.2046 lb.

The third consideration is that of viscosity. Viscosity can be compared to friction in that it is a resistance to movement between liquid particles and between solid and liquid particles. In a continuous process, such as in the production of fine aggregates, the slurry flows into and out of the classifying tank at a measurable rate, which determines its velocity of flow through the tank. The solids settle out, due to their weight, at a speed that is expressed as rate of fall or settling. It is the interrelationship between these two movements which governs the path of the falling particle. FEED

OVERFLOW DIAGRAM OF FORCES V O D A LA

LB

B

C

D

E

G PATH PATH OF PARTICLE

LC

LD

LE

HORIZONTAL TRAVEL OF FALLING SAND PARTICLES

Settling From A Surface Current

In the figure above, directions of the current and of the free fall of the particle are at right angles. The actual path of a falling particle is a parabola; the height of fall (D) and the length of horizontal travel (L) are determined by use of well-known formula. This is called settling from a surface current.

116

While a particle is in suspension, one force acts on it to make it fall, while others act to limit the fall. The force that acts downward is that of gravity (g). It has been brought out that viscosity of the liquid may slow the fall. The difference between free settling and hindered settling is a relative one between the factors causing a particle to t o fall and those restricting the fall. In free settling, the downward component is much greater than those slowing up the fall are. In hindered settling, the downward component is only slightly greater than those slowing the fall are. Apart from the multiple sizing, the scalping tank serves to eliminate the surplus water prior to discharge of product to a screw-type classifier. By so doing, the amount W of water handled by the screw classifier can be regu- A lated better for the mesh size of fines to be retained. It S H becomes apparent, then, that a water scalping tank will I N be followed by as many screw classifiers as there are G sizes of sand products to be made. / C Adjustable weirs on the scalping tank regulate the rate L A and velocity of overflow to provide the size separations S required. Clays, silt and slime, which are lighter than the S I finest mesh sand, remain suspended in the water and F Y are washed out over the tank weirs for discharge into a I N G settling pond. In order to re-blend sand fractions into a specification product, settling stations are located along the bottom length of the tank. The best classifying occurs with more length to the classifying tank. It is recommended to use a minimum of a 28’ tank. Shorter tanks will work when the material is very consistent in gradation and close to the product specification to be made. Build up or “silting in” of the classifying tank will occur as the specific gravity of the overflow slurry goes beyond 1.065. The ideal slurry is between 1.025 and 1.030. At this point, maximum efficiency occurs. Additional water will carry away more fines unless the tank area is oversized.

117

DENSITY—SPECIFIC GRAVITY RELATIONSHIP FOR WATER SLURRY OF SAND, GRAVEL, QUARTZ OR LIMESTONE (SOLID S.G. 2.65-2.70) 0

10

20

2.0

30

40

50

60

70

80 2.0

DENSITY PERCENT SOLIDS WT 1 LITER SLURRY IN GRAMS 1000 FOR THE ABOVE MATERIALS

G= 1.9

DENSITY % SOLIDS BY WEIGHT = 160 (G-1) G

1.8

DENSITY % SOLIDS BY VOLUME = 60 (G-1) 1.7

1.9

E M U L O V Y B S D I L O S R F O

T H G I E W Y B S D I L O S R F O

) G (

W

A S H I N G


1.8

1.7

) G ( P L U P 1.6 R O Y R R U L 1.5 S Y T I V A R G I 1.4 C F I C E P S

P L U P R1.6 O Y R R U L S 1.5 Y T I V A R G C I 1.4 F I C E P S

1.3

1.3 EXAMPLE FOR G = 1.25

1.2

1.2

DENSITY = 32% SOLIDS BY WT OR 15% SOLIDS BY VOL

1.1

1.1

DENSITY PERCENT SOLIDS 1.0

1.0 0

10

20

30

40

50

60

70

NOTE: 1) Most dredge and pump pump suppliers suppliers work work with percent solids by by weight. 2) A few dredge dredge suppliers work with percent percent solids by volume. 3) ALL MACHINES ARE RATED ON PERCENT SOLIDS BY WEIGHT.

118

80

SAND CLASSIFYING TANKS

Purpose: Classification is the sizing of solid particles (typi3 cally – ⁄ 8” or -#4 mesh) by means of settling. In classification, the settling is controlled so that the fines or undersize mate- W rial will flow away with a stream of water or liquid, while the A coarse or oversize material accumulates in a settled mass. S H By applying the principles of settling and classification in I N the classifying/ water scalping tank, the following functions G are performed: / C 1) Reject undesirables – remove clay, silts, slime and L A excess fine particles S 2) Separate desirable sand particles so that they can be S I controlled F 3) Reblend separated material into correct gradation Y I N specifications G 4) Production of two different specification products simultaneously and an excess product 5) Remove excess water Feed to a classifying tank is typically in the form of a sand and water slurry. The slurry feed can come from several sources, but is generally from a dredging or wet screening operation.

1) 2) 3) 4)

CLASSIFYING TANKS ARE NECESSARY WHEN ANY ONE OF THE FOLLOWING CONDITIONS EXIST: Feed material gradations fail to meet the allowable minimums or maximums when compared to the material specifications to be produced Sand feed gradations vary within a deposit More than one specification product is desired Excessive water is present, such as from a dredging operation 119

Design: A classifying tank consists of an all-welded tank of varying size ranging from 8’ x 20’ to 12’ x 48’. The slurry feed is introduced into the tank through a feed box, which includes an integral curved liner for improved slurry flow control. As the slurry flows toward the discharge end of the tank, weight differences between sand particles allow coarser material to settle first while the lighter material settles progressively further down the tank. Clays, silt and slime, which are lighter than the finest mesh sand, remain suspended in the water and are washed out over the adjustable tank weirs for discharge into a settling pond. Sand fractions are then reblended into two specification products and an excess product, via settling stations (six to 11, depending on W tank length) located along the bottom of the tank. Discharge A valves (typically three) at each station serve to “batch” the S H sand into a collecting/ blending flume located below the tank. I N VELOCITY CLASSIFICATION G FEED


Water and Slime Coarse

Medium

Fine

A

120

C B

Very Fine

Sand discharge is controlled via a controller (see section on Spec-Select™ Classifying Tank Controllers) which receives a signal from an adjustable height sensing paddle located at each station. The sensing paddle controls the amount of material that accumulates at each station before a valve opens to discharge the sand and water slurry. The valves consist of self-aligning urethane dart valves and urethane seats, providing uniform flow at the maximum rate, positive sealing and long service life. The urethane dart valve is connected to an adjustable down rod to ensure optimum seating pressure and provide leak resistant operation. The valves are activated by an electric/ hydraulic mechanism in response to signals received from the controller and sensing paddle. Once discharged, the slurry flows through product down pipes, which include urethane elbows for improved W A flow and wear into a collecting/blending flume for transport S to the appropriate dewatering screw. H I N The electric/hydraulic mechanism is mounted within a G bridge that runs lengthwise with the tank. This system C / includes an electric/hydraulic L pump, reservoir, accumulator, A individual ball, and check valves S S at each station. Also included is a I F toggle switch box, with a 3-position Y I switch for each valve at a station N G which can be “plugged in” to an C individual station, providing maxiA mum flexibility in troubleshooting B and servicing the classifying tank. Other important features of the classifying tank include stainless steel hydraulic tubing with O-ring face seal fittings, optional rising current cells to create hindered settling, optional recirculating pump to reduce overall water requirements and complete pre-wiring of the tank to a NEMA 4 junction box/control enclosure located on the bridge.

121

Application: Several factors affect the sizing and application of a classifying tank. Among these are dry material feed rate, material density, feed gradation, product gradations or specifications desired, feed source, the amount of water entering the tank with the feed material and other material characteristics such as whether the material is crushed or natural. Of these factors, four items must be known to properly size a classifying tank: • Feed rate (TPH) • Feed gradation • Feed source…Conveyor...Dredge • Product gradations or specifications desired Given the above, the classifying tank is sized based on W its water handling capacity. The requirements for water A in a classifying tank are to have approximately 10 GPM S of water for every 1 TPH of total sand feed or 100 GPM H of water for every 1 TPH of silt (-#200 mesh). The larger I N of these two figures and the desired mesh split to be pro G duced within the tank are then used to size the classifying / C tank. This process allows for proper dilution of the sand so L that the material will correctly settle in the tank for proper A S classification. The following table is provided to assist in S the proper selection of a classifying tank. I F Y CLASSIFYING TANKS I N APPROX. APPROX. NUMBER DEAD LIVE OF G WATER CAPACITIES (GPM) SIZE

LOAD (LBS)

LOAD (LBS)

DISCHARGE 200 MESH STATIONS

100 MESH

150 MESH

8’ X 20’

17,600

89,620

2300

1200

700

6

8’ X 24’

19,400

108,340

2800

1400

800

7

8’ X 28’

21,300

126,800

3200

1600

900

8

8’ X 32’

22,825

146,120

3500

1800

950

9

10’ X 24’

23,100

119,110

3500

1800

950

7

10’ X 28’

24,800

140,650

4100

2100

1100

8

10’ X 32’

26,500

161,060

4700

2400

1250

9

10’ X 36’

29,100

182,100

5300

2700

1400

10

10’ X 40’

31,800

202,010

5900

3000

1550

11

12’ X 48’

43,000

275,960

8100

4200

2150

11

NOTE: Approximated weights include three cell flume, rising current cells & manifold, discharge down pipes and handrails around tank bridge. Approximated weights DO NOT include support structure, access (stairs or ladder) and recirculating pump.

122

Classifying Tank Animation http://youtu.be/XUTUeBG4j2A

SPEC-SELECT™ CONTROLLERS Purpose: Spec-Select™ Controllers are utilized in conjunction with a classifying tank to control the blending of the various sand fractions into one or two specification products plus an excess product. Spec-Select™ Controllers are also a valuable source of information when troubleshooting or simply monitoring the activity occurring within a classifying tank.

W Design: Spec-Select™

Controllers consist of an indusA trial-quality, solid-state PLC (Programmable Logic S Controller) housed in the NEMA 4 junction box/control H enclosure located on the bridge of the classifying tank I N and a desktop PC (Personal Computer) HMI (human G machine interface). An optional industrial PC HMI with / C color touchscreen housed in a NEMA 4 enclosure is also L A available for outdoor installation in lieu of the desktop PC. S Simple, Windows-based controls are used on all sys S I F tems, allowing the operator to proportion the amount of Y material discharging from each station to the appropriate I N collecting/blending flume for transport to the dewatering G device. EEPROM memory in the PLC and the hard drive of the PC provide permanent storage PLC logic, operating parameters, recipes and the screens displayed on the HMI, which are used to create a user-friendly interface to the PLC, which actually controls the classifying tank.

Application: Two modes of controlling the tank discharge are utilized in conventional classifying tanks. The SpecSelect™ I (SSI) mode of operation is the simplest method to operate a classifying tank and is the same in theory as the manual splitter box type classifying tanks. It is an independent control of each station by a percentage method to determine the amount of material discharged to each of the three product flumes. The system operates on a 10-second cycle that is repeated over and over from product “A” to “B” to “C”. The mode of operation works best in a fairly consistent pit, where the feed gradation does not vary too much. Monitoring of the product gradations informs the operator of variances in the feed. Changes 124

to the percentage settings at each station can be made quickly at the controller to maintain the product specification. The Spec-Select™ II (SSII) mode of operation is a dependent method of operation utilizing minimum and maximum timer settings at each station to control the material discharge, and ensure that product specifications are met on a consistent basis. This system not only controls the discharge valves at each station, but also controls all of the settling stations relative to each other. The minimum and maximum timer settings are determined by the gradation of the material settling out at each station and relating this to the product specification limits. In effect, the SSII mode of operation is making batches of specification W sand continuously. Each “A” or “B” valve at a given station A discharges sand on a time basis between its minimum S H and maximum timer settings. No valve can begin a new I N batch until every other valve has discharged at least its G minimum in the present batch being made. When a valve C / reaches its maximum timer setting and one or more of L the other valves for that product have not yet met their A minimum settings, the controller automatically directs the S S material to one of the other product valves and flumes. It I F is important to remember, in this mode of operation, the Y I potential to waste or to direct sand to a non-spec product N G where it is not desired is increased and should be carefully considered when operating a tank by this method. This mode of operation is typically used when the feed gradation and/or feed rate vary widely. All currently manufactured models of Spec-Select™ Controllers are capable of operating in either the SpecSelect™ I or the Spec-Select™ II mode of operation.

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SCREENING/WASHING PLANTS

W

A S H I N G Purpose: Screening/washing plants are used to rinse and /

size up to three stone products while simultaneously washing, L dewatering and fine-tuning a single sand product. Specific stone A S product gradations can typically be met with the use of blending S gates between the screen overs chutes while sand product graI F dations are adjusted with screw speed and water overflow rates.

C

Y I N Design: Traditional Series 1800 Screening/Washing Plants G consist of a heavy-duty, three-deck incline (10°) or horizontal wet screen mounted above a fine material washer on either a semi-portable skid support structure or a heavy-duty portable chassis. Important features of the screening/washing plant include the capability to fit three radial stacking conveyors under the screen overs chutes, complete water plumbing with single inlet connection and wide three-sided screen access platform, as well as all the features of the industry-leading screens and the fine material washers.

Also available are the Model #1822PHB and Model #1830PHB Portable Screening/Washing Plants, which incorporate a blademill ahead of the horizontal screen, all on a single, heavy-duty, portable chassis. This addition serves to pre-condition the raw feed material for more efficient wet screening. Application: Review of the feed material gradation, products desired and TPH to be processed will determine the screen and screw combination best suited for the application.

126

1800 SERIES SCREENING/WASHING PLANTS Description Screen Size

Model #1822 PHB

Model #1830 PHB

6’ x 16’ (horizontal only)

6’ x 20’ (horizontal only)

Model #1814

Model #1822

Model #1830

5’ x 14’ (incline only)

6’ x 16’

6’ x 20’

36” x 25” twin

44” x 32’ twin

Fine Material Washer Size

36” x 25’ single

36” x 25’ twin

44” x 32’ twin or 36” x 25’ twin

Blademill Size

N/A

N/A

N/A

24” x 12’ twin

36” x 15” twin

Consult Factory

Consult Factory

Consult Factory

Consult Factory

Consult Factory

Up to 700 US-GPM

Up to 1200 US-GPM

Up to 2700 US-GPM

Up to 1200 US-GPM

Up to 2700 US-GPM

Plant Capacity Water Requirements

OPTIONAL EQUIPMENT (Portable and Skid Plants) Wedge Bolts (for screen cloth retention)

Yes

Yes

Yes

Yes

Yes

AR or Urethane Chute & Hopper Wear Liners

Yes

Yes

Yes

Yes

Yes

Feed/Slurry Box

Yes

Yes

Yes

Yes

Yes

Wire Mesh Screen Cloth

Yes

Yes

Yes

Yes

Yes

Deck Preparation for Urethane Screen Media

No

Yes

Yes

Yes

Yes

Electrical Pkg.

Yes

Yes

Yes

Yes

Yes

Blending Gates

Yes

Yes

Yes

Yes

Yes

W

A S H I N G


OPTIONAL EQUIPMENT (Skid Plants only) Stair Access vs. Ladder Access

Roll-Away Chutes

Yes

Yes

Yes

N/A

N/A

Yes

Yes

Yes

N/A

N/A

OPTIONAL EQUIPMENT (Portable Plants only)

Landing Gear

No

Yes

Yes

Yes

Yes

Hydraulic Run-On Jacks

No

Yes

Yes

Yes

Yes

Gas/Hyd. or Elec./Hyd. Power Pk.

No

Yes

Yes

Yes

Yes

Hyd. Screen Adjust (Incline Screens only)

No

Yes

Yes

N/A

N/A

Swing-Away Chutes

No

Yes

Yes

Yes

Yes

Cross Conveyors

No

Yes

Yes

Yes

Yes

Remote Grease

Yes

Yes

Yes

Yes

Yes

N/A

N/A

Yes

N/A

Yes

N/A

N/A

Yes

N/A

Yes

Flare Mounting in King Pin Area Hinged/ Folding Flares

NOTES: Model #1814, #1822 and #1830 available in both portable and skid-mounted configurations. Additional options exist, consult factory for further details. Skid-mounted plants can be configured to include a number of different screen and screw combinations (consult factory for details). For further capacity or specification information on KPI-JCI and Astec Mobile Screens screens, fine material washers and blademills, see the corresponding sections of this book relating to those pieces of equipment.

127

SERIES 9000 DEWATERING SCREENS

W

A S H I N G Purpose: Dewatering screens are utilized to dewater fine /

aggregates (typically, minus 3/8” or smaller) prior to stockpilL ing. Feed to a dewatering screen can come from a variety of A S sources including cyclones, conventional wet screens, density S classifiers, classifying tanks and even directly from fine mateI F rial washers. Depending on the gradation of the product to be Y produced, dewatering screens will typically produce a finished I N product with a moisture content as low as 8 – 15 percent by G weight.

C

Design: Dewatering screens are single-deck, adjustable incline (0-5°) linear motion screens available in sizes ranging from 2’ wide x 7’ long to 8’ wide x 16’ long with processing rates up to 400 stph. The units include a predominately bolted screen frame assembly, integral stiffener tubes with lifting lugs, steel coil springs, a sloped feed section, an adjustable discharge dam to control bed depth, bolt-in UHMW pan side liners, modular urethane screen media available in sizes ranging from #10 - #150 mesh, a stress-relieved fabricated motor bridge, engineered motor mounting studs and two (2) adjustable stroke 1200 rpm vibrating motors. Dewatering screens can also be configured to produce two (2) different sand products from one unit through the installation of a divider down the length of the unit and dual discharge/blending chutes.

128

Application: Several important elements must be considered when sizing a dewatering screen, product gradation, feed rate in stph and the percent solids-by-weight of the slurry feed. Generally speaking, a finer product requires a reduction in the screen stroke and a reduction in the capacity of the unit. Also, a finer product will typically have a higher moisture content than a coarse product.

W

POWER REQUIREMENTS & APPROX. CAPACITIES

A S H I N G

Capacity (STPH) Model

HP

Feed Size (assumes a 2.67 S.G.) Fine Sand (-#50 x +#325)

Coarse Sand (-#4 x +#150)

DWS 27

2 @ 2.7

13

43

DWS 38

2 @ 3.9

20

65

DWS 410

2 @ 4.7

43

144

DWS 513

2 @ 9.4

65

216

DWS 613

2 @ 9.4

78

259

DWS 716

2 @ 15.4

106

353

DWS 816

2 @ 15.4

121

403


NOTES: Capacities provided are estimates only. Consult factory for specific applications.

129

SERIES 9000 PLANTS

W

The KPI-JCI and Astec Mobile Screens Series 9000 and 1892 plants combine all the features of the KPI-JCI and Astec Mobile Screens Series 9000 dewatering screens, cyclones, slurry pumps, the conventional Series 1800 plants and custom-engi/ neered chassis or skid-mounted support structures into one C L complete, compact aggregate processing package. A • The Model #9400 plants are designed for aggregate producers S requiring a fines recovery plant to support their existing opera S I F tions by reducing the volume of fine material (typically, minus Y #100 mesh x plus #400 mesh) reporting to the settling pond I N without the use of flocculants. G • The Model #9200 plants are designed to dewater and fine-tune one or two sand products to a level typically not possible with traditional sand dewatering equipment. • The Model 1892 plants are designed for aggregate producers requiring a single plant to rinse and size up to three stone products while simultaneously washing, dewatering and fine-tuning one or two sand products.

A S H I N G

Available in portable, semi-portable or stationary configurations, these plants are custom built to meet the application requirements and can be configured with various types and quantities of cyclones, various pump sizes, various dewatering screen sizes and various incline or horizontal conventional screen sizes. Other custom features include dual inlet slurry sumps with bypass and overflow capabilities, electrical packages with variable frequency drives as required, air suspension axle assemblies, hydraulic leveling jacks, hydraulically folding cyclone support system, electric/hydraulic or gas/hydraulic power packs, roll-away or swing-away screen overs chutes, blending chutes, cross conveyors and multiple liner options. 130

NOTES:

W

A S H I N G


131

HIGH FREQUENCY SCREENS Astec Mobile Screens’ product line offers the “PEP” family of high frequency screens to include the Vari-Vibe ® and Duo-Vibe ® High Frequency Screens. There are many advantages a high frequency screen provides the material producer, from higher production capabilities to more efficient sizing as compared to conventional screens. The higher production is achieved by an aggressive screen vibration directly applied to the screen media. The high level of vibrating RPMs allow material to stratify and separate at a much faster rate, while being processed as compared to conventional screens.

S

C R E E N I N Multiple configurations for the screens are available in G stationary, portable and track mounted assemblies. Both screens provide producer with increased production, waste stockpile reduction and more salable product.

132

The Vari-Vibe ® screens are ideal for post-screening applications and offer high frequency vibration on all decks. These screens achieve the highest screen capacity in the market for fines removal, chip sizing, dry manufactured sand and more.

S C R E E N I N G

The Duo-Vibe ® screens are ideal for pre-screening applications by offering a scalper top deck with conventional frequency mounted over high frequency bottom deck(s). These screens improve production needs earlier in the circuit by removing fines from coarser materials.

High Frequency Screen Animation http://youtu.be/EJzz7wS54r4

133

1612V CAPACITY (6’ x 12’ Single Deck PEP Vari-Vibe® High Frequency Screen)

Basic Capacity Table — 1612V Through Deck, Slotted Screen

B/C, TPH sq. ft.

TPH, 72 sq. ft.

3/4”

4.60

331.2 TPH

5/8”

4.20

302.4 TPH

1/2”

3.81

274.3 TPH

3/8”

3.33

239.8 TPH

1/4”

2.91

209.5 TPH

3/16” (4M)

2.43

175.0 TPH

1/8” (6M)

1.60

115.2 TPH

3/32” (8M)

1.18

85.0 TPH

5/64” (10M)

0.90

64.8 TPH

1/16” (12M)

0.70

50.4 TPH

3/64” (16M)

0.55

39.6 TPH

1/32” (20M)

0.43

31.0 TPH

3/128” (30M)

0.33

23.8 TPH

1/64” (40M)

0.22

15.8 TPH

S C R E E N I N G

* Tonnages will vary depending on application, size and type of screens used, weight of product and moisture content. ** This chart is to be used for estimation purposes only. This chart is based on material weight of 100 lbs/cu. ft. Do not guarantee tonnages without consideration of all possible variables.

134

2618VM CAPACITY (Modified 6’ x 18’ Double Deck PEP Vari-Vibe® High Frequency Screen)

Basic Capacity Table — 2618V

Through Deck, Slotted Screen 3/4”

B/C, TPH sq. ft. 4.60

Pre-Screen Deck Chip Deck Section A Section B (TPH, 36 sq. ft.) (TPH, 72 sq, ft.) 165.6 TPH

301.5 TPH

Post Screen Fine Deck Section C TPH, 72 sq. ft.

S

265.0 TPH

5/8”

4.20

151.2 TPH

274.5 TPH

241.9 TPH

1/2”

3.81

137.1 TPH

247.5 TPH

219.5 TPH

3/8”

3.33

119.9 TPH

216.0 TPH

191.8 TPH

1/4”

2.91

104.8 TPH

189.0 TPH

167.6 TPH

3/16” (4M)

2.43

87.5 TPH

157.5 TPH

140.0 TPH

1/8” (6M)

1.60

57.6 TPH

103.5 TPH

92.2 TPH

3/32” (8M)

1.18

42.5 TPH

76.5 TPH

68.0 TPH

5/64” (10M)

0.90

32.4 TPH

58.5 TPH

51.8 TPH

1/16” (12M)

0.70

25.2 TPH

45.0 TPH

40.3 TPH

3/64” (16M)

0.55

19.8 TPH

36.0 TPH

31.7 TPH

1/32” (20M)

0.43

15.5 TPH

27.9 TPH

24.8 TPH

3/128” (30M)

0.33

11.9 TPH

21.4 TPH

19.0 TPH

1/64” (40M)

0.22

7.92 TPH

14.3 TPH

12.7 TPH

C R E E N I N G

* Tonnages will vary depending on application, size and type of screens used, weight of product and moisture content. ** This chart is to be used for estimation purposes only. This chart is based on material weight of 100 lbs/cu. ft. Do not guarantee tonnages without consideration of all possible variables.

135

TROUBLESHOOTING GUIDE: HIGH FREQUENCY SCREENS It is a good rule of thumb to ask yourself the following questions if you are seeing a change in the gradation. 1. 2. 3. 4. 5. 6. 7. 8.

Has the moisture of material changed? Is spread of material correct? Is GPM flow rate to vibrators correct? Does the angle of screen need to be changed? Has the feed gradation changed? Is there screen cloth wear? Has feed rate changed? If electric vibrators, is overload protection tripped?

It is KPI-JCI and Astec Mobile Screens’ recommendation to closely monitor the following items as conditions change. MATERIAL CARRY-OVER OF INEFFICIENT SCREENING CAUSE

S C R E E N I N G

SOLUTION

1. Bed of material is too deep

1. Decrease tonnage rate

2. Screen cloth open area too small

2. Increase open area of cloth

3. Screen cloth is blinded

3. Clean screen cloth

4. Screen cloth is blinding on the sides of panels

4. Adjust side seal strips to the same height as tappets

5. Screen angle may need to be steeper

5. Increase angle of screen (not to exceed 43°)

6. Oil flow to vibrators is not set properly

6. Check and adjust vibrators to proper settings

7. Weights in vibrators need to be increased

7. Adjust weights to a higher setting

136

TROUBLESHOOTING GUIDE: HIGH FREQUENCY SCREENS (cont.) SCREEN-CLOTH IS BLINDING CAUSE

SOLUTION

1. Material is too wet for the feed rate

1. Reduce feed rate

2. Oil flow to vibrators is not set properly

2. Check and adjust vibrators to proper settings

3. Screen angle may need to be steeper

3. Increase angle of screen (not to exceed 43°)

4. Spread of material is not even across screen panel

4. Material needs to be spread across entire screen panel for proper screening

5. Weights in vibrators need to increased

5. Adjust weights to a high setting

MATERIAL FLOWS DOWN CENTER OR TO ONE SIDE OF SCREEN CAUSE

S

SOLUTION

1. Material is not centered on feed conveyor

1. Center material on feed conveyor

2. Aggregate spreader needs to be adjusted

2. Adjust position of aggregate spreader in or out to headpulley of feed conveyor

Adjust angle irons on aggregate spreader to achieve proper spread on screen

3. Side seal strips set too high

3. Adjust side seal strips to the same height as the tappets

4. Screening plant may not be level

4. Check level of plant

137

C R E E N I N G

TROUBLESHOOTING GUIDE: HIGH FREQUENCY SCREENS (cont.) BREAKING SCREEN CLOTH CAUSE

S C R E E N I N G

SOLUTION

1. Wire diameter of screen cloth is too small for size of material

1. Incease wire diameter or decrease material size

2. Material impact on screen cloth

2. Install rubber strips across across width of cloth at impact zone to protect screen cloth

3. Improper tension of screen cloth

3. Screen cloth is either too loose or too tight (depending on wire diameter). Make sure anchor ends are evenly tensioned.

4. Bucker rubber on tappets are worn out

4. Install new bucker rubber on tappets

5. Improper weave or crimp of screen panel

5. Contact screen manufacturer

6. Screen panel is too long and hook end turned over too far

6. Contact screen manufacturer

MATERIAL IS “POP-CORNING” AS IT FLOWS DOWN SCREEN CAUSE

1. Fines have been removed from material

SOLUTION

1. Adjust oil flow on the vibrators where this is occurring Install dams to knock material down (Contact KPI-JCI and Astec Mobile Screens)

2. Feed rate to screen is too slow

138

2. Increase feed rate.

NOTES:

S C R E E N I N G

139 139

SCREENING THEORY Screening is defined as a mechanical process which accomplishes a separation of particles on the basis of size. Particles are presented to a multitude of apertures in a screening surface and rejected if larger than the opening, or accepted and passed through if smaller. The material requiring separation, the feed, is delivered to one end of the screening surface. Assuming that the openings in the screening media are all the same size, movement of the material across the surface will produce two products. The material rejected by the apertures (overs) discharges over the far end, while the material accepted by the apertures (throughs) pass through the openings. As a single particle approaches the screening media, it could come into contact with the solid wire or plate that makes up the screen media, or pass completely through the open hole. If the size of the particle is relatively small when compared to the openings, there is a high degree of probability that it will pass through one of them before S it reaches the end of the screen. Conversely, when the C particle is relatively large, or close to the same size as the R opening, there is a high degree of probability that it will E E pass over the entire screen and be rejected to the overs. N If the movement of the particle is very rapid, it might I N bounce from wire to wire and never reach an aperture G for sizing. The velocity of the particle, the incline of the screen, and the thickness of the wire all tend to reduce the effective dimensions of the openings and make accurate sizing more difficult. It becomes apparent that this simplified screen would perform much better if the following conditions prevailed: 1. Each particle is delivered individually to an aperture. 2. The particle arrives at the opening with zero forward velocity. 3. The particle traveled normal to the screen surface. 4. The smallest dimension of the particle was centered on the opening. 5. Screening surface has little or no thickness

140

As material flows over a vibrating screening surface, it tends to develop fluid-like characteristics. The larger particles rise to the top while the smaller particles sift through the voids and find their way to the bottom of the material bed. This phenomenon of differentiation is called stratification. Without stratification of the material, there would be no opportunity for the small particles to get to the bottom of the material bed and pass through the screen apertures causing separation of material by size. After the material has been stratified to allow the passage of throughs, the apertures are then blocked with oversize particles that were above the fines in the material bed. Before passage of more fines can occur, the bed must be re-stratified so the fines are again at the bottom of the bed and available for passage. Thus, the process must be repeated successively until all fines are passed. Potential occurrences that can prevent successful screening include: 1. Arrival of several particles at an aperture, with the result that none succeed in passing even though all S are undersize C 2. Oversize particles plugging the openings so that under- R E size cannot pass though E 3. Undersize particles blinding the apertures by sticking to N the screening media which reduces the opening thus I N G preventing passage of undersize particles 4. Oblique impact of near-size particles bouncing off the sides of the aperture reducing efficiency There are two basic styles of vibrating gradation screens manufactured to perform the material separation process. These include inclined screens and horizontal screens. Within these two broad definitions are many different variations which affect the screening action and mounting systems. INCLINE SCREENS are most commonly built with single eccentric shafts that create a circular motion. Dual shaft incline screens may be considered for heavier-duty applications. Incline screens utilize gravity as well as the circular eccentric motion to perform the screening operation. Depending upon application, incline screens run at angles of 10 degrees to 45 degrees. The high frequency 141

screen typically runs very steep when screening at very fine openings. A primary feature of the incline screen is its relatively low cost. It may also have a lower operating cost by using less horsepower and having fewer shafts and bearings. FACTS ABOUT INCLINE SCREENS: 1. Incline screens have an operating angle of typically 10-35 degrees. 2. Produce a higher material travel speed and a thinner bed depth than a flat screen, reducing the potential for material spill-over from volumetric surges. 3. Size for size, incline screens are more economical in terms of capital expenditure and power consumption than a flat screen, and requires fewer shaft assemblies and parts to maintain and replace. 4. The increased profile height provides more accessibility for maintenance, screen media changes, etc. 5. Circular stroke pattern produces fewer “G’s” than flat screens, more of a “tumbling” motion. The material has a tendency to pick up velocity as it moves down the deck. S 6. Can be configured to retain material on the decks longer by rotating the screen’s direction, essentially C R throwing the material backwards. E E N BASED ON THIS DATA, AN INCLINED SCREEN I N IS RECOMMENDED WHEN THE FOLLOWING G CONDITIONS EXIST:

• The producer has a relatively consistent feed volume and gradation to the screen. • The desired results can be achieved with the stroke pattern being produced by a single or dual shaft assembly. • The material is relatively dry (in dry applications) and does not plug the opening. • All of the above are true and the producer does not require a low-profile height. • Large volumetric surges of material that could potentially spill over the rear and sides of flat screens are frequent. • A replacement screen is required to fit within existing or fixed screen towers/structures. • The economics of capital expenditure and maintenance are top priority. 142

HORIZONTAL SCREENS are utilized as a low height aggressive action screening device. Horizontal screens are built with dual shaft (creating a straight line action at approximately 45 degrees to the horizontal) or triple shaft (creating an oval action with adjustable stroke angle typically between 30 and 60 degrees from horizontal). A primary feature of the horizontal screen is its aggressive action in applications where blinding or plugging of the screen media openings can occur. FACTS ABOUT HORIZONTAL SCREENS: 1. Flat screens operate at zero degrees. 2. Provide a lower profile height for increased suitability on portable plants. 3. Generates more “G” forces required to dislodge particles that might potentially blind incline screens. 4. Produces an oval stroke pattern that can be adjusted to suit the application for increased flexibility through manipulating stroke length and timing angle. 5. Triple shaft design distributes the load over a larger area and utilizes smaller bearings that can run faster and provide a longer operating life. 6. Produces a consistent material travel speed along the S C entire length of the deck. The screen can also be con- R figured to enable a slower travel speed than incline E E screens for higher efficiency. N 7. The relationship of the trajectory to the screening I N media is at a true right angle, where incline screens G essentially reduce the amount of open area. Incline screen operators often compensate for this by installing cloth with slightly larger openings than the desired top size. BASED ON THIS DATA, A HORIZONTAL SCREEN IS RECOMMENDED WHEN THE FOLLOWING CONDITIONS EXIST: • The producer requires portability to move between various sites or a lower profile height is required. • The incoming feed gradation is inconsistent. • When screening efficiency/reduced carryover is a priority. • The screen is to be used in more than one application. • A slow, consistent material travel speed is required on any or all of the decks. • The material has a tendency to plug or blind the screen cloth. 143

Figure 1

The variations in the stroke patterns of incline and horizontal screens are illustrated in Figure 1. SCREENING REVELATIONS In 2001, Johnson Crushers International, Inc. (KPI-JCI) performed a side-by-side test between flat and incline screens in an effort to better understand the benefits and limitations of both designs. This data has led to the devel S opment of the new Combo screen design, which was also C tested and compared. Listed below is a general recap of R the observations that were made: E E N MULTI-SLOPE “COMBO” SCREEN I N The Combo ® screens utilize both inclined panels and G horizontal panels: 1. Inclined panel sections increases material travel speed, thus producing thinner bed depths enabling fines to be introduced to the horizontal bottom deck faster, which increases the bottom deck screening capacity, or bottom deck factor used in the VSMA screen calculation. 2. Increased travel speed produced by incline sections reduces potential for material spillover caused by volumetric surges. 3. Horizontal panels reduce travel speed and provides high screening efficiency and reduced carryover, similar to a flat screen. 4. Only multi-slope design that utilizes a triple shaft assem-

144

bly producing oval screening motion with the ability to adjust stroke length, stroke angle, and RPM speed to best suit the conditions of the application. 5. Hybrid punch-plate in feed area provides an additional 10% of screening area, thereby removing a percentage of fines before being introduced to the actual deck. BASED ON THIS DATA, A COMBO ® SCREEN IS RECOMMENDED WHEN THE FOLLOWING CONDITIONS EXIST: • When a high percentage of fines exists in the feed material that must be separated efficiently. • When increased screen capacity is required within the same structure of “footprint.” • When an incline screen cannot produce the desired screening efficiency of separation found on horizontal screens. • To reduce material “spillover” caused by volumetric surges of feed coupled with a slower travel speed of a flat screen. • When a single “dual purpose” screen is required to separate both coarse and fine particles. S • When an incline screen is preferred, but cannot be C R installed due to height restrictions or limitations. E E N I N G

145

NOTES:

S C R E E N I N G

146

VSMA FACTORS FOR CALCULATING SCREEN AREA Formula: Screening Area = U AxBxCxDxExFxGxHxJ *Basic Operating Conditions

Feed to screening deck contains 25% oversize and 40% halfsize Feed is granular free-flowing material Material weighs 100 lbs. per cu. ft. Operating slope of screen is: Inclined Screen 18° - 20° with flow rotation Horizontal Screen 0° Objective Screening Efficiency—95% **Furnished by VSMA

U = STPH Passing Specified Aperture

FACTOR “A” Surface % STPH Square Open Passing Opening Area A Sq. Ft. 4”

75%

7.69

31 ⁄ 2”

77%

7.03

3”

74%

6.17

3

2 ⁄ 4”

74%

5.85

21 ⁄ 2”

72%

2”

FACTOR “B” (Percent of Oversize in Feed to Deck) % Oversize

5

Factor B

10

15

20

25

1.21 1.13 1.08 1.02 1.00

30

35

.96

.92

% Oversize

40

45

50

55

60

65

70

Factor B

.88

.84

.79

.75

.70

.66

.62

5.52

% Oversize

75

80

85

90

95

71%

4.90

Factor B

.58

.53

.50

.46

.33

13 ⁄ 4”

68%

4.51

11 ⁄ 2”

69%

4.20

11 ⁄ 4”

66%

3.89

1”

64%

3.56

% Halfsize

7 ⁄ 8” 3 ⁄ 4” 5 ⁄ 8” 1 ⁄ 2” 3 ⁄ 8” 1 ⁄ 4” 3 ⁄ 16” 1 ⁄ 8” 3 ⁄ 32” 1 ⁄ 16” 1 ⁄ 32”

63%

3.38

Factor C

61%

3.08

59%

2.82

54%

2.47

51%

0

5

10

15

20

25

30

.40

.45

.50

.55

.60

.70

.80

% Halfsize

35

Factor C

.90

2.08

% Halfsize

70

46%

1.60

Factor C

45%

1.27

40%

.95

45%

.76

37%

.58

Deck

Top

Second

Third

41%

.39

Factor D

1.00

.90

.80

FACTOR “H” (Shape of Surface Opening) Square Short Slot

(3 to 4 times Width)

Long Slot

(More than 4 Times Width)

1.00

40

45

50

55

1.00 1.10 1.20 1.30 75

80

85

60

S C R E E N I N G

65

1.40 1.55

90

1.70 1.85 2.00 2.20 2.40

FACTOR “D” (Deck Location)

FACTOR “E” (Wet Screening) Opening 1 ⁄ 32”

1

⁄ 16” 1 ⁄ 8” 3 ⁄ 16”

1

⁄ 4”

3

1 3 ⁄ 8” ⁄ ⁄ 4” 2”

1”

Factor E 1.00 1.25 2.00 2.50 2.00 1.75 1.40 1.30 1.25

1.15

FACTOR “F” (Material Weight)

1.20

FACTOR “J” (Efficiency) 95% 90% 85% 80% 75% 70%

FACTOR “C” (Percent of Halfsize in Feed to Deck)

1.00 1.15 1.35 1.50 1.70 1.90

Lbs./cu.ft. 150 125 100 90 Factor F

80 75

70 60 50 30

1.50 1.25 1.00 .90 .80 .75 .70 .60 .50 .30

FACTOR “G” (Screen Surface Open Area) Factor “G” = % Open Area of Surface Being Used % Open Area Indicated in Capacity

147

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148

Y M O N O C E

$ $

$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

) S E E P E R O L E S G D (

5 2 5 1

5 2 5 1

0 m 0 m m e 0 l p o p o p o 5 t t p o o o t t t i 2 t t t t t 0 o o o 0 2 l 1 0 n n n b b b u 1 o n o o m 2 n 2 o o 2 n o

g M ) U E S K E M O H I R C X A T S N I ( M

b 8 / 3

b 2 / 1

b 6 8 4 4 4 8 2 2 1 / / / / / / / 1 7 3 3 3 7 1 / 7

D b E M E P P S R

0 5 1 1 0 0 8

0 5 0 1 0 5 7

0 0 0 1 0 5 7

5 5 5 5 7 7 7 7 7 8 8 8 - 5 - 5 - 5 5 7 7 6 7 6 7 5 6

5 5 7 7 0 0 7 1 0 5 8 5 7 7 5 8

) M . G U N N I I ( 4 M N I E E X Z A P I O M S

r a b y f l 0 z 4 5 4 z i r g 8

a L ) M . I N U A R I M ( 0 I E 1 T X E A A Z I M M S

0 1 0 1 4 2 0 1 0 1 4 1 8 1 8 6 3

X I R T A G M Y N I V P N A E E L E H A C S R C S

5

x

G M N U I I P D E L A C M S

x

x

x

x

x

x

x

x

x

x

x

x

x

D G N R A I D N E N E A R T S C S

x

x x

x

x

G N E I N N E I F E R C S

x

x x

x

x

x

x

x

G T N H I P L G I L A C S

L E D O M

r a b y 5 6 2 l z z i r g

x

x

r n n y e e e e a v r n e p e r i l a S d ) e r r t l t d o a e c c y x f c p N ) e l r e c b t a E H n S S E r f a n n I t S h i t t a E i a c t m l t l d g a s c h d a S l a e l u r a r o a R c l l r n l m F i a s e n n F F Q e e n C C F F l y u I a I g ” l h d e ” i p p ” ” ” S ” v c ” l l ” s a e n ” d S i a I I s r S a S n I H S u a X e P a i e H c S n Q a t c c C i S D L C M F s d J “ ( “ ( C “ H “ S “ S “ M “ S “ F “ S

g n i n e p o r a b y l z z i r g c t . s h g d i e e e w p s a i r d e e h m g i h s a h t h i w c u s s s e r l s o t e c b a t f s u s u m o i r e a k v o r n t s o , p e u k t o n r e t s d n m p u e e m d i x s a i e m k h t r i o s w t d m e u s u i m e x b a t m s u m e d 0 e 2 e x p 8 s , r e 0 2 w o x l 7 s , - 0 2 b x 6 ” n 6 3 o g o t i n e n z e i p s o l a x i r a e t m a ” m 4 ; r o f s n e p e o r r d c s ” 6 8 1 1 x < , 6 , ” 6 2 1 1 o x 5 t , e 4 z 1 i s x 5 l a i n r o e t g a i n m n r o e p f o p x o a r d m ” ” 4 5 2 < d , d e n r i i g u s q e e d r t r a h g b i e n o h t p n o e r d d n d e e p e e f d d e r e l d i o r w t n e o b c - n a a c

149

S C R E E N I N G

Y M O N O C E ) S E E P E R O L E S G D (

$ $ $

5 3 5 1 5 1 0 5 0 1 2 1

) M E U K S M O E H I R C X A T I S N ( M

4 / 1

6 6 1 1 / 3 / 5

b D E M E P P S R

0 0 5 1 0 0 1 1

0 0 3 1 0 0 1 1

) M . U G N N I I ( M N I E E X Z A P I O M S

0 0 2 1 0 0 0 1

5 5 c . 2 . 3 2

a

S C R E E N I N G

L ) M A X . I N I U R I M R ( I E T X T A E Z A A I M M M S N E G N E Y I V P R A L E C C S H A

5

5 0 1

S

G M N U I I P D E L A C M S G T N H I P L G I L A C S D G N R A I D N E N E A R T S C S

X X X

G N E I N N E I F E R C S

X X

r d e l r y d S G d a d d L z N R n d e e e E E E n n a n i z n r i i i D B E a s l l l t e G c O L R S c c n D I n 2 I n C M O I 7 K S 1 2 7 7

150

g n m i u $ n $ m $ $ e i $ $ $ $ $ $ p a o x r m a b g y l z z 0 i r x g 2 - 8 , 2 2 5 c 0 d 2 1 1 2 - 0 - d s x 7 8 0 0 1 , 1 1 1 e e 0 p 2 s x 6 r e n h g o i g h i n h t n i e e e 6 w p 8 o 8 8 1 / s / / / s 3 3 l e x 3 3 a m e b ” t 4 s u ; s m n e e e 0 0 r k 0 c o 5 0 s r 5 t 0 0 0 9 6 s 1 1 0 , 1 - 0 x e 9 0 0 k 6 5 o , 5 5 r t 9 8 9 1 s 6 x 5 m , u 4 m 1 i x 5 a x m n o c c t g 3 4 i 6 7 h n w i n d e e p s u o e x a b m t s u ” 5 m f d 2 4 6 6 1 2 3 e e e p k s o r r e t s w d o e l x s i f - , b s g n ” i r 6 a X X 3 e o b t 4 e z h i t s i l w a i t r f e a t a h s m e l r g o n i X X f s p o r d e ” 8 s e 1 e < , r g ” e 2 d 1 5 o t 1 e X X X i a z t s s e l t a a i r r e e t a p o m n r o e e f r c p s d o r 0 X X e d 2 e x ” p 8 4 s 2 n < d e , e d r e c n r s i g i u s q e n o e d r g r t a i n h b d g X X i n e n e o h p t e p n d o e r ” d d 4 n / d e 3 e p e o e f t S d d d R i i d d ” r r d r N y E b b e e 8 e e / a n a d a y y h l v a E E t t n d d g i i 5 i a o s s i u u l l N E r n n s e w i e e t c c R H n a D D a O n e H t t e I n C o k c b S M P S I S I M n - o r a a c t s

INCLINE SCREENS

Series 70: All Series 70 screens are two bearing inclined screens and include base frame with C spring suspension and electric motor drives. These screens are a medium light-duty screen and typically are used to size material down to #4 mesh and up to 3” maximum. They are available in a range of sizes from 2’ x 4’ to 5’ x 12’. Series 71 is a “Conventional Screen” and is available in single, double- or triple-deck configurations. Each deck has side-tensioned cloth. They operate at an incline of approximately 15°.

SINGLE DECK Model 71-1D244 71-1D366 71-1D368 71-1D486 71-1D488 71-1D4810 71-1D4812 71-1D6010 71-1D6012 71-1D6014

Size 24” x 4’ 36” x 6’ 36” x 8’ 48” x 6’ 48” x 8’ 48” x 10’ 48” x 10’ 60” x 10’ 60” x 12’ 60” x 14’

Speed (RPM) 15-1700 14-1600 14-1600 14-1600 13-1500 13-1500 13-1500 13-1500 13-1500 11-1300

Motor 2 HP 3 HP 3 HP 3 HP 5 HP 5 HP 7-1/2 HP 5 HP 7-1/2 HP 10 HP

Size 36” x 6’ 48” x 6’ 48” x 8’

Speed (RPM) 14-1600 13-1500 13-1500

Motor 3 HP 5 HP 7-1/2 HP

DOUBLE DECK Model 71-2D366 71-2D486 71-2D488

151

S C R E E N I N G

71-2D4810 71-2D4812 71-2D6010 71-2D6012 71-2D6014

48” x 10’ 48” x 12’ 60” x 10’ 60” x 12’ 60” x 14’

11-1300 11-1300 11-1300 11-1300 11-1300

10 HP 10 HP 10 HP 10 HP 10 HP

Size 36” x 6’ 48” x 8’ 48” x 10’

Speed (RPM) 13-1500 11-1300 11-1300

Motor 5 HP 10 HP 10 HP

TRIPLE DECK Model 71-3D366 71-3D488 71-3D4810

Series 72 is a de-sander and is available in a doubledeck configuration. The top deck cloth is side tensioned and the bottom deck cloth is end tensioned – harp wire type. They operate at an incline of 15° to 50°.

DOUBLE DECK

S C R E E N I N G

Model 72-2D488 72-2D4810 72-2D4812 72-2D6010 72-2D6012

Size 48” x 8’ 48” x 10’ 48” x 12’ 60” x 10’ 60” x 12’

Speed 11-1300 11-1300 11-1300 11-1300 11-1300

Motor 7-1/2 HP 10 HP 10 HP 10 HP 10 HP

Series 77 is a vibrating grizzly and is available in singleor double-deck configurations. Grizzly bars are available in fixed or adjustable configurations. Single-deck configurations include grizzly bars only. Double-deck configurations include grizzly bars on the top deck and side tensioned screen cloth on the bottom deck. Coil impact springs are mounted inside of the C springs. They operate at an incline angle of approximately 15°.

SINGLE DECK Model 77-1DG-(F or A) 366 77-1DG-(F or A) 488

Size 36” x 6’ 48” x 8’

Speed 13-1500 11-1300

Motor 7-1/2 HP 10 HP

Size 48” x 8’ 48” x 10’

Speed 11-1300 11-1300

Motor 15 HP 15 HP

DOUBLE DECK Model 77-2DG-(F or A) 488 77-2DG-(F or A) 4810

Note: F = Fixed grizzly bars A = Adjustable grizzly bars

152

22° INCLINE SCREENS

These economy screens run at lower speeds and utilize gravity to assist the motion created by the eccentric shaft for moving material. The single-shaft, two-bearing design is recommended for light- to standard-duty applications. DOUBLE DECK Model 2D4812 2D6012 2D6014 2D6016 2D7216

Size 48” x 12’ 60” x 12’ 60” x 14’ 60” x 16’ 72” x 16’

Speed (RPM) 950-1050 950-1050 950-1050 950-1050 950-1050

Motor 7-1/2 HP 10 HP 15 HP 15 HP 20 HP

Size 48” x 12’ 60” x 12’ 60” x 14’ 60” x 16’ 72” x 16’

Speed (RPM) 950-1050 950-1050 950-1050 950-1050 950-1050

Motor 10 HP 15 HP 20 HP 20 HP 30 HP

TRIPLE DECK Model 3D4812 3D6012 3D6014 3D6016 3D7216

153

S C R E E N I N G

10° INCLINE SCREENS

The 10-degree incline screen combines the economy of the single-shaft, two-bearing incline screens with the heavyduty, aggressive action of the horizontal screens. Perfect for portable applications and in situations where headroom is limited, the screen has a 3/8 inch circular stroke and runs at an RPM around 950. The heavy-duty pan and deck construction make it perfect for applications ranging from standard to heavy-duty. DOUBLE DECK Model C 2D3610 R E 2D4810 E 2D4812 N 2D6012 I N 2D6014 G 2D6016 2D7216 2D7220 * 2D9620

S

Size 36” x 10’ 48” x 10’ 48” x 12’ 60” x 12’ 60” x 14’ 60” x 16’ 72” x 16’ 72” x 20’ 96” x 20’

Speed (RPM) 850-950 850-950 850-950 850-950 850-950 850-950 850-950 850-950 850-950

Motor 7-1/2 HP 10 HP 15 HP 20 HP 25 HP 30 HP 30 HP 30 HP 40 HP

Size 36” x 10’ 48” x 10’ 48” x 12’ 60” x 12’ 60” x 14’ 60” x 16’ 72” x 16’ 72” x 20’ 96” x 20’

Speed (RPM) 850-950 850-950 850-950 850-950 850-950 850-950 850-950 850-950 850-950

Motor 10 HP 15 HP 20 HP 25 HP 30 HP 40 HP 40 HP 40 HP 50 HP

TRIPLE DECK Model 3D3610 3D4810 3D4812 3D6012 3D6014 3D6016 3D7216 3D7220 * 3D9620

NOTE: *2D9620 and 3D9620 screens operate at 15° incline.

154

INCLINE SCREENS Incline screens feature heavy-duty side and reinforcing plates, huck bolted construction, an adjustable operating incline from 15-25 degrees, adjustable stroke amplitudes, AR lined feed boxes, and heavy-duty double-roll bronze cage spherical roller bearings. Incline screens are available in both single- and dual-shaft arrangements, two- and three-deck configurations, and are available in sizes ranging from 6’ x 16’ up to 8’ x 20.’

PATENT PENDING

S

C R E E SINGLE-SHAFT INCLINED SCREENS N Single-shaft incline screens are well-suited for stationary I N installations, for applications where the feed gradation to the G screen is constant, or when a circular stroke pattern will provide the desired results. Incline screens also enable a lower bed depth of material due to an increased material travel speed that minimizes power consumption while maximizing access for maintenance. Screen size: 6162 & 6163 6202 & 6203 7202 & 7203 8202 & 8203

155

CASCADE SCREEN

The Cascade ® Incline Screen from KPI-JCI and Astec Mobile Screens is a field-proven and reliable design featuring an externally-mounted vibrating assembly engineered for efficiency and reduced cost of operation. The screen is available in two or three decks and various sizes. Additionally, the screens are available with either S oil or grease lubrication and optional speed/stroke combi C nations which allow for optimum separation and increased R efficiency. As your screen ages, it is not always costE E effective to replace or modify the entire support structure N or chassis so KPI-JCI and Astec Mobile Screens is willI N ing to collect data on your aging machine assembly and G design and manufacture a replacement “drop-in” unit to minimize any interruption to your production. Screen Size 5162-26 SIC 5163-26 SIC 6162-26 SIC 6163-26 SIC 6202-32 SIC 6203-32 SIC

156

Horsepower 25 25 25 25 25 30

Weight 12,000 lbs 15,500 lbs 13,000 lbs 16,620 lbs 15,750 lbs 19,850 lbs

Cascade Screen Animation http://youtu.be/gj2HmYxvfGA

Decks 2 3 2 3 2 3

DUAL SHAFT INCLINED SCREENS In addition to the benefits described of the single shaft incline designs, dual-shaft incline screens will provide increased bearing life as compared to a single-shaft arrangement, due to the load being distributed over additional bearing surface. In some cases, dual-shaft screens will also provide the benefit of a more aggressive screen action in applications where the feed end of the screen becomes “top heavy” with a high volume of material.

S C R E E N I N G

PATENT PENDING

Screen size: 6162 & 6163 6202 & 6203 7202 & 7203 8202 & 8203

157

SCALPING SCREENS

MESABI (PIONEER) TYPE SINGLE SHAFT 4-BEARING STANDARD DUTY DOUBLE DECK

S C R E E N I N G

Model 2D4810 2D4812 2D6012 2D6014 2D7216

Size 48” x 10’ 48” x 12’ 60” x 12’ 60” x 14’ 72” x 16’

Speed (RPM) 950-1000 950-1000 950-1000 950-1000 950-1000

Motor 20 HP 25 HP 30 HP 40 HP 50 HP

Size 48” x 8’ 60” x 14’ 72” x 14’

Speed (RPM) 900 900 900

Motor 30 HP 40 HP 50 HP

HEAVY DUTY Model 2D488 2D6014 2D7214

158

HORIZONTAL VIBRATING SCREENS Horizontal screens are of a triple-shaft design that provides a true oval vibrating motion, and feature a huck-bolted basket assembly, fully-contained lubrication system, and rubber springs to reduce basket stress. Their low profile height makes them ideal for portability, and their adjustment capabilities of speed, stroke length, and stroke angle enable them to be well suited for both fine and coarse screening applications. Horizontal screens can be retrofitted with either wire cloth or urethane panels, and can be easily converted to wet screen applications. Horizontal screens are available in several configurations in sizes ranging from 5’ x 14’ up to 8’ x 20’ in both two and three-deck designs. PATENT PENDING

S

C R E FINISHING SCREENS The finishing screen maximizes screening efficiency and E N productivity in fine separation applications by using a I N reduced stroke and a higher frequency that provides an G optimal sifting action. Adjustable stroke length (Amplitude) (Stroke reduced by removing weight plugs.) Adjustable stroke angle (Timing angle) Operating speed range Maximum feed size Maximum top deck opening Screen size: 5142-32FS & 5143-32FS 5162-32FS & 5163-32FS 6162-32FS & 6163-32FS 6202-32FS & 6203-32FS 7202-38FS & 7203-38FS 8202-38FS & 8203-38FS

1 2” min 3 ⁄ 8” to max ⁄

30 to 60 degrees 875-1075 rpm 8” All model screens = 2”

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STANDARD SCREENS The Standard Series are best suited for the widest array of applications ranging from fine to coarse material separation applications.

PATENT PENDING

Adjustable stroke length (Amplitude) (Stroke reduced by removing weight plugs) Adjustable stroke angle (Timing angle) Operating speed range Maximum feed size Maximum top deck opening

S C R E E N I N G

5 3 8” to max ⁄ 4” min ⁄

30 to 60 degrees 675-875 rpm 10” 514, 516 & 616 = 5” 620, 720, 820 & 824 = 4”

Screen size: 5142-32LP & 5143-32LP 5162-32LP & 5163-32LP 6162-32LP & 6163-32LP 6202-32LP & 6203-32LP 7202-38LP & 7203-38LP 8202-38LP & 8203-38LP 8242-38LP & 8243-38LP & 8243-38LP *All screen sizes listed above are available in 2 ½ degree slope models

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MEDIUM SCALPER SCREENS The Medium Scalper Screen is an excellent machine for coarse screening and light-duty scalping applications. Medium Scalper Screens also feature thicker side plates and a heavy-duty crowned top deck .

PATENT PENDING

Adjustable stroke length (Amplitude) Adjustable stroke angle (Timing angle) Operating speed range Maximum feed size* Maximum top deck opening Screen size: 5142-32MS & 5143-32MS 5162-32MS & 5163-32MS 6162-32MS & 6163-32MS 6202-32MS & 6203-32MS 7202-38MS & 7203-38MS 8202-38MS & 8203-38MS

16” to max ⁄ 4” min ⁄ 16 30 to 60 degrees 675-875 rpm 14” All model screens = 5” 9

3

161

S C R E E N I N G

HEAVY SCALPER SCREENS The Heavy Scalper Screens are designed for heavy-duty scalping applications by implementing the lowest frequency and most aggressive stroke length in the family of Horizontal Screens. Heavy scalper screens also feature the heaviest-duty construction that can accept up to 18” feed sizes and 24” in the extra-heavy step deck model.

PATENT PENDING

Adjustable stroke length* (Amplitude) (Stroke reduced by removing weight plugs) Adjustable stroke angle (Timing angle) Operating speed range* Maximum feed size* Maximum top deck opening* Screen size: 5142-32HS & 5143-32HS 5143-32HS 5162-32HS & 5163-32HS 6162-38HS & 6163-38HS 6202-38HS & 6203-38HS 7202-38HS 8202-38HS

S C R E E N I N G

3 7 4” to max ⁄ 8” min ⁄

30 to 60 degrees 575-775 rpm 18” All model screens = 6”

EXTRA-HEAVY SCALPER SCREENS The Extra-Heavy Scalper Screens are also available with a stepped grizzly bar top deck designed to handle up to 24” feed size.

Screen size: 5142-32XH 5162-32XH 6162-38XH 6202-38XH 7202-38XH 8202-38XH

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MULTI-ANGLE SCREENS 20 ° 10 ° 0° 20 ° 10 °

0°

20 ° 10 ° 0°

PATENT PENDING

Combo ® Screens combine the advantages of both an inclined screen and a horizontal screen. The screen is equipped with incline panel sections that begin with a 20-degree section, flatten to a 10-degree section, and the remaining deck area is at zero degrees. By installing sloped sections at the feed end, material bed depth is reduced since gravity will increase the travel speed of the material. This reduced bed depth minimizes spillover, and enables fine particles to “stratify” through the coarser particles and onto the screening surface S much faster, where it can then find more opportunities C to be passed through screen openings. This design also R E enables fines to be introduced to the bottom deck faster, E which increases the bottom deck screening capacity, or N N bottom deck factor used in the VSMA screen calculation. I G They have also designed a punch plate section into the feed plate itself, thereby increasing the total screening area of the top deck by an additional 10%. This punch plate will remove a high percentage of fine particles before they are even introduced to the actual screen deck, thereby increasing production volumes. The coarse “near” size and “over” size particles that are not initially separated on the middle and top decks gradually slow down as the deck panels flatten out to the horizontal section towards the discharge end of the screen. This material’s reduced travel speed, combined with the optimum angle of trajectory in relationship to the screen opening, provides a high screening efficiency upon which oval motion horizontal screens have built their reputation.

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The Combo ® Screen is also the only multi-slope design that features a triple-shaft design. This design provides an optimal oval screening motion that has proven effective over decades of success in the company’s traditional flat screen design. In addition to the features of the Combo ® design, producers will also benefit by having the ability to adjust stroke length, stroke angle and RPM speed to best suit the conditions of the application. The end result is a machine that: 1) Provides increased feed production by as much as 20% over standard flat or incline screens; 2) Maintains or improves the screening efficiency of separation found on horizontal screens; 3) Reduces material spillover at the feed end from high volumes or surges of feed material; 4) Improves the bottom screen deck’s utilization, thereby increasing volume and efficiency. Although not as portable as the traditional horizontal screens, the Combo ® design will be an ideal screen for S a variety of both scalping and product sizing applica C tions. The design is especially well suited for accepting R large volumetric feed ‘surges,’ deposits containing a high E E percentage of fines that must be removed, installations N where screening capacity must be increased within the I N same structural or mounting ‘footprint,’ or in closed circuit G with crushers. Combo ® Screens are available in both a standard-duty and finishing-duty three-deck configurations and are currently available in 6’ x 20’, 7’ x 20’ and 8’ x 20’ sizes. Combo ® Screens feature huck-bolt construction, incline deck panels that slope from 20 to zero degrees, adjustable stroke amplitudes, a hinged tailgate rear section for maintenance access, and a perforated feed box for additional screening area. Combo ® Screens can be installed with either standard wire cloth or urethane/ rubber deck panels.

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COMBO SCREEN

PATENT PENDING

Adjustable stroke length (Amplitude) (Stroke reduced by removing weight plugs) Adjustable stroke angle (Timing angle) Operating speed range Maximum feed size Maximum top deck opening Screen size: 6202-32CS & 6203-32CS 7202-38CS & 7203-38CS 8202-38CS & 8203-38CS

5 3 8” to max ⁄ 4” min ⁄

30 to 60 degrees 675-875 rpm 10” 4”

S C R E E N I N G

COMBO ® FINISHING SCREENS The finishing screen maximizes screening efficiency and productivity in fine separation applications by using a reduced stroke and a higher frequency that provides an optimal sifting action. Adjustable stroke length (Amplitude) (Stroke reduced by removing weight plugs.) Adjustable stroke angle (Timing angle) Operating speed range Maximum feed size Maximum top deck opening Screen size: 6202-32CF & 6203-32CF 7202-38CF & 7203-38CF 8202-38CF & 8203-38CF

Combo Screen Animation http://youtu.be/0DMYEV392z8

min 3 ⁄ 8” to max 1 ⁄ 2” 30 to 60 degrees 875-1075 rpm 8” All model screens = 2”

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GUIDELINES FOR STROKE ADJUSTMENTS Size of Material

Plug Configuration

RPM of Screen

Timing Angle

Coarse 1 4” Plus 1 ⁄

3 Plugs Each Wheel 3 4” Approximately ⁄

Very Slow 740 RPM

45° - 55°

2 Plugs Each Wheel 11/16” Approximately

Slow 3 1 4” to 1 ⁄ 4” ⁄ 785 RPM

40° - 50°

Fine 3 1 ⁄ 4” - 1 ⁄ 4”

1 Plug Each Wheel 5 ⁄ 8” Approximately

Fast 3 1 4” to 1 ⁄ 4” ⁄ 830 RPM

35° - 45°

Extra Fine 3 8” Minus ⁄

No Plugs Each Wheel 9 ⁄ 16” Approximately Minimum Stroke

Very Fast 875 RPM

2 e Medium r u 3 1 4” - 1 ⁄ 4” ⁄ g i F

S C R E E N I N G

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30° - 40°

FRACTIONATING RAP Price increases in liquid asphalt and virgin aggregates continue to climb is leading the industry to re-evaluate the use of recycled asphalt pavement (RAP) in hot mix asphalt (HMA) designs. Consider that recycled asphalt has rock the same age as the aggregate coming from the rock quarry today and liquid asphalt coming from the refined oil from oil wells. Most RAP processed today is 1/2" x 0, since it is coming from milled material which is generally surface mix. Processing RAP includes crushing and/or screening. The fractionation process typically separates RAP into two or three sizes, 1/2" x 3/8”, 3/8" x 3/16", and -3/16”. The coarser material (fractions) will have lower asphalt content and dust content versus the finer material (fractions), which enables the mix designer to have greater control over the amount of RAP being introduced into the mix. Under the assumption that recycled materials are worth what they replace, producers are realizing extraordinary financial benefits by fractionating RAP material.

S C R E E N I N G

To determine exactly what being FRAP Ready could mean to your operation, go to www.befrapready.com and enter your data into the electronic calculator for your total saving per year.

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INTRODUCTION Asphalt mixes first appeared in the United States in the late 1800s. Natural asphalt from Trinidad Lake was placed in drums and imported into the United States where drums were heated and the asphalt melted to be mixed with combinations of aggregate of various sizes to produce a smooth, quiet road. Professor Alonzo Barber of Harvard College obtained a franchise from the British Government to bring Trinidad Lake asphalt into the United States and distribute it. From these early beginnings, asphalt roads have grown to become the major pavement of choice with approximately 94% of the roads in America being surfaced with asphalt. In the early 1900s, due to high cost of the Trinidad Lake material, recycling of old pavements was common. During the 1920s, with more and more automobiles becoming available, the demand for roads increased. Concurrent with this was the need for more fuel, and as oil was discovered in Pennsylvania and California, Trinidad Lake asphalt was replaced by a less expensive product, the residue from the refining process (the bottom of the barrel) and the roads were made from asphalt being derived from the oil refining process. Due to the fact that liquid asphalt was difficult to handle, sticky, and at low temperatures a rubbery-like S substance, oil refineries just wanted to be free of the material C and basically gave it away initially. Due to the abundance of R E crude oil in Texas and other areas of the United States, asphalt E and oil remained relatively cheap through the ‘50s, ‘60s and into N the early ‘70s.

I N G During the 1950s and ‘60s, liquid asphalt sold for approximately

$20/ton. Since an average of 5% asphalt was used to glue the aggregate together to form a road, the glue or asphalt only costs approximately $1/ ton and aggregate was approximately $1/ton, leading to a virgin material costs of the hot mix asphalt of approximately $2/ ton. By the early ‘70s, liquid asphalt had increased to approximately $30/ton, with the asphalt or glue at $1.50/ton and aggregate to about $1.50/ ton, resulting in material costs of $3/ton.

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F1 In 1973, crude oil prices escalated due to the first oil embargo in the United States and liquid asphalt prices escalated to $80/ton in a very short time period. Typically, asphalt prices per ton are usually 6 times the price of a barrel of crude oil, i.e. 6 x $30/ barrel equals $180/ton liquid asphalt. This also resulted in higher aggregate prices (due to higher fuel prices) and liquid asphalt prices of approximately $4/ton of mix (5% of $80/ton). And thus resulting in a total virgin material cost of $6-$7/ton.

Again in 1979, F1 , crude climbed to $30/barrel and liquid asphalt prices escalated to $180/ton with the second oil embargo. This resulted in material costs for the asphalt portion of hot mix at $9/ton and aggregate costs had escalated to approximately $4-$5/ton resulting in a total virgin material costs of $13/ton. In 1975, two things came together that made recycling again economically feasible. First, the prices of liquid asphalt and aggregate had escalated as mentioned above and secondly, a machine called a road planer or milling machine was developed ( F2), that would remove as little as a 1/4” or as much as 6” of material from the roadway in one pass. This revolutionary new machine allowed S numerous benefits to the C road building industry. R

E E N I N G

A few of them are as follows: • Rutted roads could be milled to a level surface, resulting in a more uniform and higher-quality pavement when placed over a flat surface, F3. • Drainage could be maintained on city streets by milling the road surface prior to placement of another lift of mix eliminating stacking of layer on layer of resurfacing material, F4. • Milling eliminated the raising of utilities and manholes and maintained proper drainage to the curb, F5.

169 169

• Milling eliminated the reduction in clearance under overpasses, F6. • Milling eliminated the increase of weight on bridges caused by adding layer after layer. While all of these advantages helped the public works designers to establish and maintain elevations, clearances, etc., it also generated an enormous amount of reclaimed pavement that could be recycled. A second contribution of milling machines to the asphalt industry was the reduction in cost of obtaining recy S cled material versus C R complete pavement E removal. Early millE ing costs were in the N I $4/ton range, but curN G rently milling costs of $2-$3/ton, depending whether on highway or in city work, is normal. With the combination of higher virgin material costs and lower removal costs, hot mix asphalt has become the highest volume recycle product in the United States. The low cost of milling material versus the higher costs of virgin material produces a differential that gives recycle a tremendous economic advantage. Basically, recycling is worth what it replaces. F7 shows the economic benefit of adding recycle based on the various percentages used. While recycling is often looked at in many industries as an inferior product to new materials, in hot mix asphalt it is often found to be a superior product since the liquid asphalt available today is often not of the same quality as it was a number of years

170

ago. Current specifications allow the artificial softening of harder asphalts and lead to liquids with high percentages of volatiles and less binding strength than the original liquid. Even where current liquids are used today, the light oils are generally evaporated during mixing and placement and over a period of time resulting in purer asphalt occurring in the recycled product. In addition, aggregates that tend to be absorptive only absorb the liquid asphalt one time. The recycled product, when combined with new aggregate, often will have a thicker film due to the fact that absorption does not occur but once in the RAP portion of the mix. Perhaps the best description of recycling could be summed up by the words of a Japanese customer (who was the first to recycle in Japan). When asked what he told his customers concerning recycle, he said “it’s all the same age.”

S C R E E N I N G

171 171

AVAILABILITY OF RECYCLED ASPHALT PRODUCTS (RAP) Due to the benefits of milling in cities and on highways, more recycle is becoming available. Inlays are becoming commonplace in most states where 1-1/2” to 2” of material is milled and a new surface is installed in the removed area without increasing the elevation of the road. This type of construction is very beneficial since the inlay area allows containment of the new mix on each side, resulting in superior joints. Also, it permits construction to be done at night with minimum disruption to the traveling public, F8 . This type of construction results in enough material being available to produce 100% recycle mix and although this is not practical, it results in increasing quantities of RAP. In addition, with rebuilding of sewers, electrical lines, and other C utilities below the roadway, numerous amounts of ripped-up R E material is available. Milling on parking lots is often done rather E than complete removal, since material can be milled to an exact N elevation and the price of milling is much less than total excaI N vation and re-grading prior to placing a new surface. This also G results in a large quantity of material being available. With the passage of each year, it is our opinion that the amount of recycle available will increase steadily and more efforts must be made to increase the quality of recycle placed into hot mix asphalt without sacrificing quality.

S

172

PROCESSING RAP MATERIAL Hot mix asphalt producers generally have two types of recycle asphalt that is available: Ripped up material being brought in by customers and mill material from highway projects, parking lots, city streets, etc. Typically, mill material is placed in recycle bins and the oversized mill material passes over a single- or multiple-deck screen. The bulk of the material is fed directly to the plant without processing. When RAP is screened over 1-1/2” to 2” screens, unless the asphalt plant has a long mixing time, the RAP cannot be totally melted and homogeneously mixed with the new virgin aggregate and asphalt. Some plants are equipped with closed circuit crushing systems that crush the oversized material that does not pass through the screen and returns it to the top of the screen as shown in F9.

S C R E E N I N G

Ripped up material has been crushed through various types of crushing plants F9 and F10. For percentages of RAP of less than 15-20%, feeding one size of material is generally adequate, but as the percentage of recycle increases, and the quality of mix is more scrutinized, it has become more obvious that multiple sizes of RAP will be required. Logic dictates that RAP should be treated like any other aggregate that is sized and fed to the plant in multiple sizes, if

173 173

the quality of the final product is to be ensured. On most mixes designed in the United States in the last 50 years, a film thickness of 9 to 10 microns has been commonplace. By sizing the material into specific size ranges, the amount of liquid asphalt in each of these materials is much more consistent. Trying to produce a product using 30, 40 or 50% RAP with one size results in segregation of the material and wide variations in liquid asphalt content, making it very difficult for the plant to produce a high¼” x 0” RAP (left), ½” + (right) quality mix. The most economical way of processing RAP into multiple sizes is to screen it first. Since most of the mill material is surface mix, it is 1/2 inch or 12.5 mm minus S material. With mill C material, 70-80% of the R material will pass a 1/2 E ½” x ¼” RAP E inch screen and if sized N into two sizes, a 1/4” x I N 0” F12, and 1/2” x 1/4” G F13 , the consistency and the percentage of RAP that can be used increases significantly. F14 shows a portable, high-frequency screen. It is self-contained with its own engine FOLD ‘N GO and hydraulic drives that allow prescreening of RAP into three sizes, one oversized and two finished products. Since 70-80% of the material will pass 1/2” minus opening, only 20-25% of the oversized material requires crushing. A highly-mobile unit such as this can be moved quickly between multiple plants sizing the material and reducing the amount of material required to be crushed. It is estimated that pre-screening the material, as shown here in F14, can be done for $.50 to $.75 per ton, therefore reducing the 174

cost of crushing significantly, since only 20-25% of the material will be required to be crushed. A crusher, as shown in F16, can then be used to feed the material directly into a prescreening unit, again sizing the material into two different sizes.

COST OF SCREENING

CRUSHER AND 5030 SCREENING PLANT

S C R E E N I N G

175 175

ECONOMICS By processing the material into two different sizes, higher percentage of RAP can be accurately blended producing not only additional savings but also resulting in a higher quality, more consistent mix and elimination of penalties. With the more restrictive gradation requirements of the Superpave mix design procedure, producers often find it difficult to insert more than 10% RAP when using only a single size. By separating the RAP into two sizes, producers are successfully increasing RAP quantities to as high as 40% while also improving the quality of the mix. F17 shows a 12.5 mm Superpave mix with 15% recycle. By fractionating the RAP, the percentage of recycle can be increased S C to 40%. The savings R through increased recyE cle is shown in F18. F19 E N shows a mix with RAP I increased from 10% to N G 35%. F20 shows the savings by increasing the RAP percentages from 10% to 35% and F22 shows a 9.5 mm mix with RAP increased from 15% to 40%. Innovative operators have used the pre-screening plants for producing a large number of multiple sizes. Where SMA mixes are required, minus-16 mesh RAP can be processed, producing a minus-16 mesh product and feeding it directly into the asphalt plant while also producing two additional sizes of product that can be used in mixes at a later date. By using the minus 16 mesh or minus-4 mesh product to replace mineral

176

filler and a portion of the polymerized asphalt, the cost of mix can be reduced significantly. F23 shows the gradations and asphalt content of the two RAP products. F24 shows the savings that result. F25 shows how the RAP actually improves the rutting performance. When using minus-16 mesh RAP, the material should be fed directly from the screen to the RAP feeder on the asphalt plant due to its high asphalt content. F26 shows a screening plant feeding directly to a RAP bin. The other two sizes are stockpiled for future use. Since the percentage of liquid varies with the size of RAP, 1/4” x 0” RAP may have as high as 7% liquid, while 1/2” x 1/4” may have less than 4% liquid. Some states place limits on the percentage of RAP before the grade of liquid is changed. Using finer RAP allows a significant reduction of new liquid without exceeding the percentage of RAP required. Most important when considering the use of multiple sizes of RAP is the improvement in quality. One producer, using 3/4” minus RAP, was limited to 20% and con-

S C R E E N I N G

177 177

tinuously experienced penalties for quality. By sizing the RAP, the percentage has increased to 40% and penalties have disappeared.

S C R E E N I N G

178

CONCLUSION With each passing year, the amount of recycle materials available continually increases. The economic benefits of adding recycle are obvious. An increase of 10% recycle can be shown to reduce the cost (based on the economics in F7). This significant savings certainly justifies processing RAP and treating it like any other material. High-frequency screening plants can reduce the cost of processing RAP significantly. These highlyportable plants make multiple sizes of recycle available to allow the production of high-quality mixes. The savings can result in paybacks in just a few months on the screening plant while improving the quality of the finished product and resulting in better, smoother, higher-quality roads for the traveling public to use.

S C R E E N I N G

179 179

MATERIAL HANDLING Belt conveyors are designed to carry material via the shortest distance between the loading and unloading points. When required, belt conveyors can operate continuously without loss of time and are capable of handling tonnages of bulk materials that would be more costly and often impractical to transport by other means. This often avoids confusion, delays and safety hazards of rail and motor traffic in plants and other congested areas. Choosing the right conveyor starts with looking at the five basic considerations: Material characteristics, conveyor length and/or discharge height, TPH feed, conveyor width and horsepower requirements. 1. Material Characteristics a. Variables include: Particle shape, particle size, moisture, angle of repose, lump size and percentage fines and weight. Characteristics normally used as a rule of thumb include: 100 lbs. per cubic foot density, 37 degree angle of repose and less than 25% of a max. 3” lump. RECOMMENDED MAXIMUM ALLOWABLE INCLINE FOR BULK MATERIALS

M A T E R I A L

H

A N D L I N G

Material Alumina Ashes, Coal, Dry, 1/2” and Under Ashes, Coal, Wet, 1/2” and Under Ashes, Fly Bauxite, Ground, Dry Bauxite, Mine Run Bauxite, Crushed 3” and Under Borax, Fine Cement, Portland Charcoal Cinders, Blast Furnace Cinders, Coal Coal Bituminous, Run of Mine Bituminous, Fines Only Bituminous, Lump Only Anthracite, Run of Mine Anthracite, Fines Anthracite, Lump Only Anthracite, Briquettes Coke—Run of Oven Coke, Breeze Concrete—Normal Concrete—Wet (6” Slump) Chips—Wood Cullet Dolomite, Lumpy Grains—Whole Gravel—Washed Gravel and Sand Gravel and Sand Saturated Gypsum, Dust Aerated

180

° Angle Incline 10-12

% Grade 17.6-21.2

20-25

36.4-46.6

23-27 20-22 20 17

42.4-50.4 36.4-40.4 36.4 30.6

20 20-25 23 20-25 18-20 20

36.4 36.4-46.6 42.4 36.4-46.6 32.5-36.4 36.4

18 20 16 16 20 16 12 18 20 15

32.4 36.4 28.6 28.6 36.4 28.6 21.3 32.4 36.4 26.8

12 27 20 22 15 15 20

21.3 50.9 36.4 40.4 26.8 26.8 36.4

12 23

21.3 42.4

Material Gypsum, 1/2” Screening Gypsum, 1-1/2” to 3” Lumps Earth—Loose and Dry Lime, Ground, 1/8” and Under Lime, Pebble Limestone, Crushed Limestone, Dust Oil Shale Ores—Hard—Primary Crushed Ores—Hard—Small Crushed Sizes Ores—Soft—No Crushing Required Phosphate Triple Super, Ground Fertilizer Phosphate Rock, Broken, Dry Phosphate Rock, Pulverized Rock, Primary Crushed Rock, Small Crushed Sizes Sand—Damp Sand—Dry Salt Soda Ash (Trona) Slate, Dust Slate, Crushed, 1/2” and Under Sulphate, Powder Sulphate, Crushed—1/2” and Under Sulphate, 3” and Under Taconite—Pellets Tar Sands

° Angle Incline 21

% Grade 38.3

15 20

26.8 36.4

23 17 18 20 18

42.4 30.6 32.5 36.4 32.5

17

30.6

20

36.4

20

36.4

30

57.7

12-15 25 17 20 20 15 20 17 20

21.2-26.8 46.6 30.6 36.4 36.4 26.8 36.4 30.6 36.4

15 21

26.8 38.3

20 18 13-15 18

36.4 32.5 23.1-26.8 32.5

NOTE: *When mass slips due to water lubrication rib type belts permit three to five degrees increase.

b. Material characteristics can affect other elements of conveyor selection. • Heavier material or large lumps may require more HP, heavier belt, closer idler spacing and impact idlers at feed points • Abrasiveness may require wear liners or special rubber compositions • Moisture may require steeper hopper sides, wider belts, anti-buildup return idlers and special belt wipers • Dust content may require special discharge hoods and chutes, slower belt speeds and hood covers • Sharp materials may require impact idlers, wear liners, special belt and plate feeder • Lightweight materials may require wider belts and less horsepower c. Conveyor Belt A conveyor belt consists of three elements: Top cover, carcass and bottom cover. The belt carcass carries the tension forces necessary in starting and moving the loaded belt, absorbs the impact energy of material loading, and provides the necessary stability for proper alignment, and load support over idlers, under all operating conditions. Because the primary function of the cover is to protect the carcass, it must resist the wearing effects of abrasion and gouging, which vary according to the type of material conveyed. The top cover will generally be thicker than the bottom cover because the concentration of wear is usually on the top or carrying side.

M

A T E R I The belt is rated in terms of “maximum recommended A L operating tension” pounds per inch of width (PIW). The H PIW of the fabric used in the belt is multiplied by the num- A ber of plies in the construction of the belt to determine the N D total PIW rating of the belt. L I N G

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d. Idlers Idler selection is based on the type of service, operating condition, load carried, and belt speed. CEMA IDLER CLASSIFICATION Classification

Former Series No.

Roll Diameter (Inches)

Description

A4 A5 B4 B5 C4 C5 C6 D5 D6 D7 E6

I I II II III III IV NA NA VI V

4 5 4 5 4 5 6 5 6 7 6

Light Duty Light Duty Light Duty Light Duty Medium Duty Medium Duty Medium Duty Medium Duty Medium Duty Heavy Duty Heavy Duty

2. Length

Length is determined one of three ways: a. Lift Height Required: When lift height is the determining factor, as a rule of thumb, an 18-degree incline is used, where 3 x height needed approximates the conveyor length required. Particle size, moisture and other factors affect the maximum incline angle. If the material tends to M have a conveyable angle that is less than 18 degrees, A a longer conveyor needs to be selected to achieve the T desired lift height. E R I A b. Distance to Be Conveyed L H c. Stockpile Capacity Desired A N D L I N G

182

T E E F N I N O I T A V E L E

’ 0 6

° ° 8 1 1 2

T R A H C N O I T A V E L E R O Y E V N O C

’ 0 5

° 5 1

’ 0 4

° 2 1

’ 0 3

’ 0 2

’ 0 ’ 1 5

° 9

’ 0 5 1 ’ 0 5 1

T E E F N I ’ 0 H 2 T 1 G N E L ’ R 0 0 O 1 Y E V N ’ O 0 C 8

’ 0 2 1 ’ 0 0 1

’ 0 8

’ 0 6 ’ 0 5 ’ 0 4

T E E F N I E C N A T S I D L A T N O Z I R O H

M A T E R I A L

’ 0 6 ’ 0 5

H

’ 0 4

A N D L I N G

183

C Head L

L

H

2'

CONVEYOR ELEVATION Conveyor Length

Conveyor Angle

Height (ft.)

40 40 40 40 60 60 60 60 80 80 80 80 100 100 100 100 125 125 125 125 150 150 150 150

12 15 18 21 12 15 18 21 12 15 18 21 12 15 18 21 12 15 18 21 12 15 18 21

10.3 12.4 14.4 16.3 14.5 17.5 20.5 23.5 18.6 22.7 26.7 30.7 22.8 27.9 32.9 37.8 28.0 34.4 40.6 46.8 33.2 40.8 48.4 55.8

M A T E R I A L

H

A N D L I N G

184

Pulley

CONICAL STOCKPILE CAPACITY Volume

H

D

6 8 10 12 14 16 18 20 22 24

16 21 26 31 36 42 47 52 57 63

Tons (100 lbs. Cu. Yds. /cu. ft.)

14 34 66 114 181 270 384 527 701 911

19 46 89 154 244 364 519 711 947 1229

H

D

26 28 30 35 40 45 50 55 60

68 73 78 91 104 117 130 143 156

Volume Tons (100 lbs. Cu. Yds. /cu. ft.)

1158 1446 1779 2824 4216 6003 8234 10960 14228

1563 1952 2401 3813 5691 8104 11116 14795 19208

LIVE STORAGE

"H"

DEAD 37.5

o

37.5

o

STORAGE

"D" APPROX

Live Capacity is the part of pile that can be removed with one feed chute at 1 4 of gross capacity of pile. the center of pile. Approximately ⁄

M A T E R I A L

GROSS VOLUME = ⁄ 3 Area Base x Height *GROSS VOLUME, (V1) Cu. Yd. = .066 (Height, Ft. )3 *GROSS CAPACITY, Tons = 1.35 x Volume, Cu. Yd. (100#/Cu. Ft.) *Based on an angle of repose of 37.5° 1

H

A N D L I N G

185

APPROXIMATE VOLUME OF CIRCULAR STOCKPILE

V3 = V1 + V20 V3 = Total Volume of Stockpile - in cu. yds. V1 = Volume of Ends (Volume of Conical Stockpile) - in cu. yds. V2 = Volume of Stockpile for 1° Arc - in cu. yds. 2 H R V = 1187 2

H = Height of Stockpile - in feet R = Radius of Arc (C Pile Pivot) - in feet L to C L R = cos 18° x conveyor length L NOTE: V2 based on 37.5° angle of repose - = Angle of Arc - in degrees 0 V1 2

R

M A T E R I A L

VOLUME OF STOCKPILE SEGMENT FOR 1o ARC V2

H

A N D L I N G

V1 2

186

V2 = Volume of Stockpile Segment for 1 degree Arc (cu. yds.) Radius (in feet) 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150

Stockpile Height (H) in Feet

10 2.1 2.5 2.9 3.4 3.8 4.2 4.6 5.1 5.5 5.9 6.3 6.7 7.2 7.6 8.0 8.4 8.8 9.3 9.7 10.1 10.5 11.0 11.4 11.8 12.2 12.6

15

20

25

30

35

40

45

50

55

6.6 7.6 8.5 9.5 10.4 11.4 12.3 13.3 14.2 15.2 16.1 17.1 18.0 19.0 19.9 20.9 21.8 22.7 23.7 24.6 25.6 26.5 27.5 28.4

16.8 18.5 20.2 21.9 23.6 25.3 27.0 28.6 30.3 32.0 33.7 35.4 37.1 38.8 40.4 42.1 43.8 45.5 47.2 48.9 50.5

31.6 34.2 36.9 39.5 42.1 44.8 47.4 50.0 52.7 55.3 57.9 60.6 63.2 65.8 68.4 71.1 73.7 76.3 79.0

56.9 60.7 64.4 68.2 72.0 75.8 79.6 83.4 87.2 91.0 94.8 98.6 102.4 106.1 109.9 113.7

87.7 92.9 98.0 103.2 108.4 113.5 118.7 123.8 129.0 134.2 139.3 144.5 149.6 154.8

134.8 141.5 148.3 155.0 161.8 168.5 175.2 182.0 188.7 195.5 202.2

187.7 196.2 204.7 213.2 221.8 230.3 238.8 247.4 255.9

252.7 263.3 273.8 284.3 294.9 305.4 315.9

344.0 356.8 369.5 382.3

Examples: L

Feet 60 80 100 120 150

H

Feet 20.5 26.7 32.9 39.1 48.4

R

Feed 57 76 95 114 142.5

V1

Cu. Yds. 567 1,254 2,346 3,938 7,469

V1

V2

Tons Cu. Yds. 766 20.2 1,693 45.6 3,167 86.6 5,316 146.8 10,083 281.2

V2

Tons 27.3 61.6 116.9 198.2 379.6

V3 V3 90° 90° stockpile stockpile Cu. Yds. Tons 2,385 3,223 5,358 7,237 10,140 13,688 17,150 23,154 32,777 44,247

3. TPH Feed

See belt carrying capacity chart. As a rule of thumb, at 350 fpm, 35 degree troughing idlers and 100 lbs/cu. ft. material, a 24” belt carries 300 TPH, a 30” belt carries 600 TPH and a 36” belt carries 900 TPH.

187

M A T E R I A L

H

A N D L I N G

0 8 6 0 4 2 9 0 4 0 1 9 2 9 6 4 7 1 1 6 2

0 1 5 3

8 8 4 4

2 9 5 5

0 6 1 . 8 s

9 5 2 0 9 6 8 4 2 5 7 2 7 4 5 3 7 1 1 1 2

7 1 2 3

4 1 1 4

6 2 1 5

0 8 4 7

5 0 5 0 5 0 7 9 0 0 5 2 5 4 3 6 6 0 1 1 2

5 2 9 2

0 4 7 3

0 6 6 4

0 0 8 6

1 4 2 4 7 3 8 3 9 6 4 9 5 9 1 1 6 2

6 6 3 3

4 9 1 4

0 2 1 6

2 4 0 8 0 7 6 4 2 6 2 7 5 8 1 1 3 2

2 9 9 2

8 2 7 3

0 4 4 5

3 3 7 2 2 1 4 4 6 5 0 4 5 7 1 1 1 2

8 1 6 2

2 6 2 3

0 6 7 4

3 5 6 5 4 2 5 9 4 5 3 7 3 6 9 1 1

4 4 2 2

6 9 7 2

0 8 0 4

2 2 0 7 5 0 6 3 3 9 1 3 5 7 1 4 1

0 7 8 1

0 3 3 2

0 0 4 3

0 4 0 6 2 7 6 3 3 8 1 2 4 6 8 1

6 9 4 1

4 6 8 1

0 2 7 2

S D E E P 0 0 S 5 1 4 3 S U O I * R r u A 0 6 o 0 7 V H . 4 2 r T e M . A P P . s Y F n T o d s 0 1 I T C 5 4 e n 3 e i p 2 A y P t S i A t l a C c e p B a 0 7 G C 0 N I 3 0 2 Y R R A 0 2 C 5 7 2 1 T M L E A B T R 0 8 0 3 E O 2 1 R Y E I A V L N H O 0 C 5 3 0

2 8 0 8 2 7 1 7 2 9 4 9 2 7 6 7 1 3 1 1 1 3 4 6 8 1 1 0 2

A N D L I N G

0 0 2 5 8 1 5 8 2 9 6 0 3 1 1 4 8 4 3 6 1 1 2 3 4 5 7 9 3 1 s h t e 8 4 0 6 2 8 4 0 2 t l h d e c B i n 1 2 3 3 4 4 5 6 7 W I 188

d r a o b t r . i k v s e o o b n a d d n a e t s s i l r e y l t d i i c a e p e r a c g e e d h t 5 f 3 o , l l % o 0 r 3 8 , % e 5 s 7 o e p s e r u f , o g n e i l z g i n a s r o e y e e r v g n e d o c 5 r . o 7 f 3 e h t s u i w T o . t . f . n o u c i t / c . b l e s s 0 s 0 1 o r c g n l l i u h f g i e a w n o l a d i e r s e t a a b l m a n i o c t e d r e o s e a h b t s s i i y y t i t i c c a a p p a a C C * * : E T O N

4. Conveyor Width

There are a number of factors that affect width. These include TPH feed, future considerations, lump size and the percentage of fines, cross-section of how the material settles on the belt, and material weight. a. Normally, portable conveyors are set up to run at 350 feet per minute, as this is accepted as the best speed for the greatest number of types of material and optimum component life. When it is desirable to run at a different speed, this will usually be a factory decision based on the material and the capabilities requested by the customer. These variations are generally applicable on engineered systems.

RECOMMENDED MAXIMUM BELT SPEEDS Belt Speeds (fpm)

Belt Width (inches)

Grain or other free-flowing, nonabrasive material

500 700 800 1000

18 24-30 36-42 48-96

Coal, damp clay, soft ores, overburden and earth, fine-crushed stone

400 600 800 1000

18 24-36 42-60 72-96

Heavy, hard, sharp-edged ore, coarse-crushed stone

350 500 600

18 24-36 Over 36

Material being conveyed

M

Foundry sand, prepared or damp; shakeout sand with small cores, with or without small castings (not hot enought to harm belting)

350

Any width

Prepared foundry sand and similar damp (or dry abrasive) materials discharged from belt by rubber-edged plows

200

Any width

Nonabrasive Materials discharged from belt by means of plows

Feeder belts, flat or troughed, for feeding fine, nonabrasive, or midly abrasive materials from hoppers and bins

A T E R I A L

H

200 except for wood pulp, where 300 to 400 is preferable

Any width

50 to 100

Any width

A N D L I N G

189

b. Lump size and the percentage of fines can have a major effect on width selection. As a rule of thumb, for a 20-degree surcharge angle, with 10 percent lumps and 90 percent fines, the recommended maximum lump size is one third of the belt width (BW/3). With all lumps and no fines, the recommended maximum lump size is one fifth of the belt width (BW/5). For a 30-degree surcharge angle, with 10 percent lumps and 90 percent fines, the recommended maximum lump size is one sixth of the belt width (BW/6). With all lumps and no fines, the recommended maximum lump size is one tenth of the belt width (BW/10). Belts must be wide enough so any combination of lumps and fine material do not load the lumps too close to the edge of the belt. c. The cross section of how the material settles on a moving belt can have a major effect on expected tonnage for a given width conveyor.

FACTORS AFFECTING THE CROSS SECTION ARE: • The angle of repose of a material is the angle that the surface of a normal, freely formed pile, makes to the horizontal. • The angle of surcharge of a material is the angle to the horizontal that the surface of the material assumes while the material is at rest on a moving conveyor belt. This angle usually is 5° to 15° less than the angle of M repose, though in some materials it may be as much A as 20° less. T E • The flowability of a material, as measured by its R angle of repose and angle of surcharge, determines I A the cross-section of the material load that safely can L H be carried on a belt. It also is an index of the safe angle of incline of the belt conveyor. The flowability A N is determined by such material characteristics as size D and shape of the fine particles and lumps, roughness L I N or smoothness of the surface of the material particles, G proportion of fines and lumps present, and moisture content of material.

190

FLOWABILITY—ANGLE OF SURCHARGE— ANGLE OF REPOSE Very free flowing 5° Angle of surcharge

Free flowing 10° Angle of surcharge

0°-19° Angle of repose


Average Flowing 20° Angle of 25° Angle of surcharge surcharge



Sluggish 30° Angle of surcharge

40°-up Angle of repose

MATERIAL CHARACTERISTICS Uniform size, very small rounded particle, either very wet or very dry, such as dry silica sand, cement, wet concrete, etc.

Rounded, dry polished particles, of medium weight, such as whole grain or beans.

Irregular, granular or lumpy materials of medium weight, such as anthracite coal, cottonseed meal, clay, etc.

Typical common Irregular, materials such as stringy, fibrous, bituminous coal, interlocking matestone, most ores, ial, such as wood etc. chips, bagasse, tempered foundry sand, etc.

d. The material weight affects the volume, which affects the width. Most aggregate weighs between 90-110 lbs. per cubic foot. When the weight varies significantly, it can have a dramatic effect on expected belt width needed to achieve a given tonnage. 5. HP Requirements

The power required to operate a belt conveyor depends on the maximum tonnage handled, the length of the conveyor, the width of the conveyor and the vertical distance that the material is lifted. Factors X + Y + Z (from tables below) = Total HP Required at Headshaft. The figures shown are based on average conditions with a uniform feed and at a normal operating speed. Additional factors such as pulley friction, skirtboard friction, material acceleration and auxiliary device frictions (mechanical feeder, tripper, etc.) may require an increase in horsepower.

M A T E R I A L

H

A N D L I Drive efficiency is taken into consideration to determine N G the motor horsepower required. This can be an additional 10-15% above the headshaft HP. The ability to start a loaded conveyor will also require an additional HP consideration. 191

FACTOR X - HORSEPOWER REQUIRED TO OPERATE EMPTY CONVEYOR AT 350 FPM Conveyor Width

25’

50’

75’

100’

150’

200’

250’

300’

350’

400’

18”

0.7

0.8

0.9

1.1

1.2

1.3

1.4

1.7

1.8

2.0

24”

0.9

1.1

1.2

1.4

1.6

1.8

2.0

2.1

2.3

2.5

30”

1.4

1.6

1.8

1.9

2.2

2.5

2.8

3.0

3.2

3.5

36”

1.8

2.0

2.1

2.6

2.9

3.1

3.4

3.8

4.2

4.4

42”

2.1

2.5

2.7

3.0

3.5

3.7

4.2

4.6

5.3

6.0

48”

2.7

2.8

3.2

3.4

3.7

4.2

5.3

5.6

6.2

6.7

Center-Center of Pulleys

FACTOR Y - ADDITIONAL HP REQUIRED TO OPERATE LOADED CONVEYOR ON THE LEVEL TPH

25’

50’

75’

Center-Center of Pulleys 100’ 150’ 200’ 250’

100

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.3

1.4

1.5

150

0.8

0.9

1.0

1.1

1.3

1.5

1.7

1.9

2.1

2.3

200

1.0

1.2

1.3

1.5

1.7

2.0

2.2

2.5

2.8

3.0

250

1.3

1.5

1.6

1.9

2.1

2.5

2.8

3.1

3.5

3.8

300

1.5

1.8

2.0

2.3

2.6

3.0

3.3

3.8

4.2

4.5

350

1.8

2.1

2.3

2.6

3.0

3.5

3.9

4.4

4.9

5.3

400

2.0

2.4

2.6

3.0

3.4

4.0

4.4

5.0

5.6

6.0

500

2.5

3.0

3.3

3.8

4.3

5.0

5.5

6.3

7.0

7.5

600

3.0

3.6

3.9

4.5

5.1

6.0

6.6

7.5

8.4

9.0

700

3.5

4.2

4.6

5.3

6.0

7.0

7.7

8.8

9.8

10.5

800

4.0

4.8

5.2

6.0

6.8

8.0

8.8

10.0

11.2

12.0

900

4.5

5.4

5.9

6.8

7.7

9.0

9.9

11.3

12.6

13.5

1000

5.0

6.0

6.5

7.5

8.5

10.0

11.0

13.0

14.0

15.0

300’

350’

400’

FACTOR Z - HORSEPOWER REQUIRED TO LIFT LOAD ON BELT CONVEYOR

M A T E R I A L

H

A N D L I N G

TPH

10’

20’

30’

40’

Lift 50’

100

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

150

1.5

3.0

4.5

6.0

7.5

9.0

10.5

12.0

13.5

15.0

200

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

20.0

250

2.5

5.0

7.5

10.0

12.5

15.0

17.5

20.0

22.5

25.0

300

3.0

6.0

9.0

12.0

15.0

18.0

21.0

24.0

27.0

30.0

350

3.5

7.0

10.5

14.0

17.5

21.0

24.5

28.0

31.5

35.0

400

4.0

8.0

12.0

16.0

20.0

24.0

28.0

32.0

36.0

40.0

500

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

600

6.0

12.0

18.0

24.0

30.0

36.0

42.0

48.0

54.0

60.0

700

7.0

14.0

21.0

28.0

35.0

42.0

49.0

56.0

63.0

70.0

800

8.0

16.0

24.0

32.0

40.0

48.0

56.0

64.0

72.0

80.0

900

9.0

18.0

27.0

36.0

45.0

54.0

63.0

72.0

81.0

90.0

1000

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0 100.0

192

60’

70’

80’

90’

100’

HOW TO DETERMINE CONVEYOR BELT SPEED Five factors are required to determine conveyor belt speed. A = Motor RPM B = Motor Sheave Dia. (inches) C = Reducer Sheave Dia. (inches) D = Reducer Ratio E = Dia. of Pulley (inches) A x B ÷ C = Reducer Input Speed (RPM) Reducer Input Speed (RPM) ÷ D = Drive Pulley RPM Drive Pulley RPM x 0.2618 x E = Conveyor Belt Speed (FPM) Example: Determine Conveyor Belt Speed of a 30” x 60’ conveyor with a 15 HP, 1750 RPM electric motor drive, 16” head pulley, 6.2” diameter motor sheave, 9.4” diameter reducer sheave and a 15:1 reducer. A = 1750 RPM B = 6.2 C = 9.4 D = 15 E = 16 1750 x 6.2 ÷ 9.4 = 1154 RPM (Reducer Input)

M

1154 RPM ÷ 15 = 77 RPM (Pulley Speed)

A T E R 322 FPM Conveyor Belt 77 RPM x 0.2618 x 16 = I A Speed L

H

NOTE: 1. To speed up the conveyor belt, a smaller reducer sheave could be used or a larger motor sheave could be used. 2. To slow down the conveyor belt, a larger reducer sheave could be used or a smaller motor sheave could be used.

A N D L I N G

193

KPI-JCI and Astec Mobile Screens manufactures a variety of portable and stationary conveyors designed to meet the customer’s requirements. As a rule of thumb, conveyors are designed with a Class I Drive, 220 PIW 2-ply belt, 5” CEMA B idlers and a belt speed of 350 fpm. At 350 fpm belt speed, basic capacities are: 24” belt width up to 300 TPH; 30” belt width up to 600 TPH; 36” belt width up to 900 TPH. CONVEYOR OPTIONS include: belt cleaners; vertical gravity take-up; horizontal gravity take-up; snub pulley; return belt covers; full hood top belt covers; impact idlers; self-training troughing idlers; self-training return idlers; 3 1 220 PIW 2-ply belting with ⁄ 16” bot16” top covers and ⁄ 3 tom covers; 330 PIW 3-ply belting with ⁄ 16” top covers and 1 16” bottom covers; CEMA C idlers; walkway with hand ⁄ rail, toeplate and galvanized decking; safety stop switch with cable tripline; discharge hood; wind hoops; balanced driveshaft; backstops; etc.

M A T E R I A L

H

A N D L I N G

194

Series 13: Portable, standard-duty, lattice frame conveyors. Most often used as radial stacking conveyors. Top folding option for road portability.

M A T E R I A L

H

A N D L I N G

195

SUPERSTACKER™

SuperStackers™ are portable, heavy-duty, telescoping radial stacking conveyors. Because of the stacker’s ability to move in three directions (raise/lower, radial and extend/ retract), it is effective in reducing segregation and degradation of material stockpiles. Unique axle arrangement allows for quick set-up of stacker. Road travel suspension of (8) eight 11:00-22.5 tires on tandem walking beam axle. Gull wing radial stockpiling axle assembly of (4) four 385/65D-19.5 tires. Gull wing is hydraulically actuated to lift travel tires off the ground for radial stockpiling. (2) Two hydraulic planetary power travel drives are included.

M Automated stockpiling with PLC controls is available on A all models. T E R I A L

H

A N D L I N G

196

SuperStacker™ Animation http://youtu.be/9Duj61MdvDs

S E M U L O V E L I P K C O T S

R E K C A T S L A I D A R L A N O I T N E V N O C

M

R E K C A T S R E P U S

A T E R I A L

H

A N D L I N G

197

2 2 8 3 0 6 e 9 8 8 n l 7 2 6 i 5 3 7 o 9 1 , 8 , 4 , p e T 6 , , , 2 k 2 4 8 1 1 3 c m o u t l S 7 9 o 0 5 9 7 1 . 6 ° V 8 4 4 2 V 0 6 7 . 9 6 0 3 , , 7 , , , , 3 5 C 2 1 3 6 9 1 2 0 0 8 1 7 2 e 2 5 l n 7 3 0 8 i 8 2 o 7 , 4 , p e T 8 , 4 , 7 , 8 , 2 k 1 3 5 c 1 2 m o u t S l o 3 5 4 7 3 9 8 . ° V 6 8 2 0 9 0 V 9 . 3 5 2 5 4 , 8 , , , , , 7 C 1 2 4 6 9 1 1 2 7 6 7 1 1 1 e n 6 5 3 8 6 l 7 i o 0 9 2 9 2 , , , , , , p T e 3 1 1 3 4 7 1 k m c o u l t o 7 S V 8 0 8 . 0 9 5 ° 4 9 9 7 V 1 9 0 . 4 3 6 3 , , 2 , 3 , 5 , 0 9 C 7 1 1 S R e E n n 7 6 7 2 2 o 9 1 O c K r 1 2 4 6 1 r A T C o F e A r e e T g . m S l e V 0 1 6 7 u D 7 2 . 1 2 3 4 8 C L o V A I D T . 6 8 3 4 5 3 e A e i v r o t 6 1 R m L S 1 9 1 9 2 2 4 9 7 u L l o A V 6 0 3 N l n 4 4 2 e 7 0 7 o 6 7 7 i 1 7 1 O , 1 , 3 , T 2 4 7 1 I P l T a c N i n E 1 . 5 1 2 1 9 o 5 5 V V C 9 5 7 7 2 . 3 , , 1 3 5 8 C N 1 2

O C

M A T E R I A L

0 3 2 , 6 6 9 5 0 , 9 4

2 9 4 , 2 1 1 7 2 3 , 3 8

5 4 1 , 6 4 2 8 1 , 4 3

2 5 3 , 8 7

0 6 0 , 6 2

2 1 2 , 4 4

4 0 3 , 9 1

0 5 7 , 2 3

9 3 0 , 8 5

3 9 2 7 2 3 5 1 6 1 8 2 4 9 4 , 1

8 1 5 , 2

5 7 9 , 5

2 7 0 , 0 1

6 2 4 , 4

1 6 4 , 7

8 2 6 7 1 1 3 7 O 7 5 0 7 4 8 9 1 1 1 0 2 7 1 5 3 R 9 1 3 2 2 3 3 4 3 5 3 6 t e e F n I s n o i s n e m i D

H

A N D L I N G

6 6 7 4 5 4 D 3 5 2 6 0 7 6 8 0 1 2 1 4 . H 4 1

5 5 . . 7 0 1 2

6 . 3 2

7 . 6 2

9 . 2 3

6 . 0 4

4 . 8 4

0 . R 8 3

6 . 1 . 7 7 4 5

6 . 6 6

1 . 6 7

9 1 . . 8 5 9 1 1

7 . 2 4 1

0 2 5 0 L 0 5 4 0 5 0 6 0 7 0 8 0 1 1 1 198

2 8 7 6 2 9 e 1 2 l n 4 i 9 7 , 8 , o , , p 1 T 5 1 5 1 e k 0 9 9 c 1 2 m o u t 4 4 S l 9 8 o 6 5 . 6 4 ° V Y 0 9 5 5 , , 0 . , , 7 2 9 7 1 4 C 1 2 7 6 1 1 2 5 9 3 3 2 e 5 7 4 n l i 5 6 , 9 , o , , p 5 0 T 6 3 e k 4 6 6 0 c 1 1 m o u t S l 9 o 6 7 4 8 . ° V 1 6 6 3 0 Y 3 1 3 , . , , , 8 4 7 8 C 9 1 4 4 7 0 1

3 1 9 e 5 6 6 l n i 9 6 8 o , , , p T 9 0 5 e k 3 3 5 c m o u t l S 0 3 0 o . 9 1 0 ° V Y 6 7 4 0 . , , , 7 9 2 1 C 2 2 2 4 0 8 9 e 4 4 6 n l i 7 1 7 o , , , p T 7 1 8 e k 2 2 3 c m o u t l S o 5 6 8 . ° V 4 6 2 0 Y 6 6 7 . , , , 8 5 8 C 0 1 2 1 2

1 0 2 2 0 2 4 5 e n l 2 6 4 9 o i , , , , T p 7 5 9 9 e k 3 3 5 7 m c o u l t o 6 4 4 S V . 3 6 8 6 2 ° Y E 5 3 1 2 0 . , , , , L 9 7 6 4 9 C I 2 2 4 5 P K e n c C O n 6 2 1 7 o 2 1 1 7 r O T 3 5 6 3 r T o A F S e e e r g . 2 1 0 2 L m e Y u D L l . 4 2 3 2 8 3 0 5 C o U V F T 0 4 9 . 8 e 1 4 0 6 — e i v r 2 1 8 o , 2 , 3 , 3 , t 2 L S m 5 u ™ o S l V 6 3 7 2 R 5 8 n e 4 6 l E 4 o i 5 , 9 , , , T 8 P 3 8 K 7 7 1 1 l C a c A i 4 T n 0 5 4 . 6 o 1 0 6 Y 0 S C . 8 6 9 , , , , C R 5 5 9 4 1 E P 3 9 5 5 . . . . U 9 5 8 8 O 7 8 S 1 1 0 2 3 2

7 3 5 9 2 6 e n l 5 6 6 o i , , , T p 5 1 1 e D k 1 1 2 m c E o u l t T o 6 9 . 0 A S 0 5 V ° 1 Y 6 0 0 . , 6 , G , 6 C 1 8 E 9 1 1 R G e n c n 6 5 0 E o 3 0 9 O r S T 1 1 1 r E F o A D e e e r g . 1 8 1 Y m e Y u . 0 L l D C 1 7 4 1 o E V T E T L . 8 0 2 e 4 v r P e i 2 3 o , t 8 5 1 L S m 1 M l u O o C V 4 2 9 n e 1 2 6 l o i 3 1 5 ™ , 2 , 4 , T 3 P S l a R c i E n 2 4 . 5 o 5 7 8 K Y C . 5 5 , , , C C 2 1 3 3 A T 5 5 5 S 7 9 7 . 9 . 9 . R O 0 5 4 6 E 1 1 1 P

6 . R 2 6 t e e F n I s n o i s n e m i D

6 . 3 6

7 . 5 7

2 . 0 8

3 3 . . 8 2 5 2 5 0 D 2 1 1 1 6 1 1 H 4 4 2 4 5 0 6 7 . 6 R 1 1

3 . 8 . 3 . 2 2 8 2 5 1 3 1 1 6 0 0 0 3 5 7 3 L 1 1 1 1 S S S S S S S S

U

S

t e e F n I s n o i s n e m i D

5 7 . R 3 4

M A T E R I A L

5 5 7 7 . . 7 8 3 4

5 5 . 5 . . D 7 5 7 8 7 9

H

A N D L I N G

4 . 7 H 3 3 8 2 3 7 R 0 1

2 . 1 2 2 1 1 1

0 6 0 3 3 5 L 1 1 1 S S S S S S 199

R E K C A T S G N I P O C S E L E M T A T E R I A L

H

A N D L I N G

200

k c o t s g n i t a e r c f o e l b a p a c t i s e . k a h t m g n e ™ r l e e k c m a a t s S e r h e t p f u o S r e e k h t c a f t o s n l a o i i t c d r a a g d n r i a p d o n c a s t e s l e a t e n a h h T t y : t i y t i c c a a p p a a c C e r e o l i m p k % c 0 o 3 t S h t r i e w g s r l e a i L p

HOPPER / FEEDERS • Gravity feed hoppers are used primarily in freeflowing materials and are installed directly over the conveyor tail end and are used with top loading equipment. • Feeder hoppers generally provide a more accurate metering of material than a gravity hopper. • Belt feeder/hopper – Belt feeders are commonly used and recommended for handling sand and gravel and sticky materials, such as clay or topsoil that tend to build-up in other types of feeders. A hopper is mounted above the feeder for use with top loading equipment. • Reciprocating plate feeders/hoppers – Reciprocating plate feeders are used for free-flowing sand and gravel to minimize impact directly to the conveyor belt. A hopper is mounted above the feeder for use with top loading equipment. • Gravity feed dozer trap is used primarily for freeflowing materials when push loading material with a dozer. Material feeds directly to conveyor belt. • Belt feeder/dozer trap includes belt feeder as described above with feed coming from a dozer, pushing material into the dozer trap. • Plate feeder/dozer trap includes plate feeder as described above with the feeder coming from a dozer pushing material into the dozer trap.

M A T E R I A L

H

A N D L I N G

201

PUGMILLS & PUGMILL PLANTS

(Model 52 shown)

KPI-JCI and Astec Mobile Screens Pugmill Plants feature aggressive mixing action and portability. The continuous mix pugmill includes two counter rotating shafts with paddles, along with timing gears that provide optimum speed to obtain the quality mix desired. Controlled blending and automatic proportioning ensures your end product is the consistency you require. Multiple configurations of ingredient feed systems ensure maximum flexibility and unparalleled ease of operation. AVAILABLE MODELS:

M A T E R I A L

Model

Primary Hopper

Top Opening

Secondary Hopper

Top Opening

Pugmill Size

Capacity

52

9 cu. yards

12’x6’

6.5 cu yards

12’x6’

4’6’/ 60 HP

up to 300 TPH

52S

15 cu. yards 14’x7’

8 cu. yards

14’x7’

4’x8’/ 100 HP

up to 500 TPH

H

A N D L I N G

202

RAILROAD BALLAST Ballast is a relatively coarse aggregate which provides a stable load carrying base for trackage as well as quick drainage. Ballast normally would be crushed quarry or slag materials: free of clay, silt, etc. Two typical specifications follow, to provide some idea as to general gradations: Sieve Opening

Example “A” Percent Passing

3” (76.2 mm)

Example “B” Percent Passing

100

1 2 ⁄ 2” (63.5 mm)

90 -100

100

2” (50.8 mm)

96 -100

1 1 ⁄ 2” (38.1 mm)

25 - 60

35 - 70

1” (25.4 mm)

0 - 15

3 4” (19.0 mm) ⁄

0 - 13

1 ⁄ 2” (12.7 mm)

0- 5

0- 5

NOTE: The above are typical. However, there are many other ballast sizes dependent on job specifications. Note also that ballast is most usually purchased on a unit volume rather than tonnage basis.

Quantities of Cement, Fine Aggregate and Coarse Aggregate Required for One Cubic Yard of Compact Mortar or Concrete Mixtures Cement

Approx. Quantities of Materials Fine Aggregate

Coarse Aggregate

Cu. Ft.

Cu. Yd.

Cu. Ft.

Cu. Yd.

15.5 12.8 11.0 9.6

23.2 25.6 27.5 28.8

0.86 0.95 1.02 1.07

C.A. F.A. (Gravel Cement (Sand) or Stone) in Sacks

1 1 1 1

1.5 2.0 2.5 3.0

1 1 1 1

1.5 2.0 2.0 2.0

3 2 3 4

7.6 8.3 7.0 6.0

11.4 16.6 14.0 12.0

0.42 0.61 0.52 0.44

22.8 16.6 21.0 24.0

0.85 0.61 0.78 0.89

1 1 1 1

2.5 2.5 2.5 3.0

3.5 4 5 5

5.9 5.6 5.0 4.6

14.7 14.0 12.5 13.8

0.54 0.52 0.46 0.51

20.6 22.4 25.0 23.0

0.76 0.83 0.92 0.85

1 sack cement = 1 cu. ft.; 4 sacks = 1 bbl.; 1 bbl. = 376 lbs.

203

RIPRAP Riprap, as used for facing dams, canals and waterways, is normally a coarse, graded material. Typical general specifications would call for a minimum 160 lb./ft.3 stone, free of cracks and seams with no sand, clay, dirt, etc. A typical specification will probably give the percent passing by particle weight such as: Percent Passing

15” Blanket

24” Blanket

100 50 - 70 30 - 50 0 - 15

165 lbs. 50 lbs. 35 lbs. 10 lbs.

670 lbs. 200 lbs. 135 lbs. 40 lbs.

In order to relate the above weights to rock size, refer to the following size/density chart: Weights of Riprap—Pounds Solid Rock Density—Lbs. Per Ft.3 (Approx.)

Cubical Size (in.)

145

150

155

160

165

170

175

180

185

5

10

11

11

12

12

12

13

13

13

6

18

19

19

20

21

21

22

23

23

7

29

30

31

32

33

34

35

36

37

8

43

44

46

47

49

50

52

53

55

9

61

63

65

68

70

72

74

76

78

10

84

87

90

93

95

98

101

104

107

11

112

116

119

123

127

131

135

139

142

12

145

150

155

160

165

170

175

180

185

13

184

191

197

203

210

216

222

229

235

14

230

238

246

254

262

270

278

286

294

15

283

293

302

312

322

332

342

351

361

16

344

356

367

379

391

403

415

426

438

17

412

426

440

454

469

483

497

511

526

18

489

506

523

539

556

573

590

607

624

19

575

595

615

634

654

674

694

714

734

20

671

694

717

740

763

786

810

833

856

22

893

925

954

985

1016

1047

1078

1108

1139

24

1160

1200

1239

1279

1319

1359

1399

1439

1479

25

1475

1526

1575

1626

1677

1728

1779

1830

1881

28

1842

1905

1967

2031

2094

2158

2222

2285

2349

30

2265

2343

2419

2498

2576

2654

2732

2811

2889

32

2749

2844

2936

3031

3126

3221

3316

3411

3506

34

3298

3412

3522

3636

3750

3864

3978

4092

4206

36

3914

4050

4180

4316

4451

4586

4722

4857

4992

39

4978

5150

5321

5493

5664

5836

6008

6179

6351

NOTE: The above is given as general information only; each job will carry its individual specification.

204

MOTOR WIRING AT STANDARD SPEEDS From National Electrical Code ==Min.

HP.

==Min. **Max. Full Size Size Rating Full Size Size Load Wire Conof Load Wire ConAmp. AWG duit Branch Amp. AWG duit Per Rubber in Circuit Per Rubber in Phase Covered Inches Fuses Phase Covered Inches

**Max Rating of Branch Circuit Fuses

Single-Phase Induction Motors 1 2 ⁄ 3 4 ⁄

1 1 1 ⁄ 2 2 3 5 1 7 ⁄ 2 10 ==,**

120 Volts 7 14 9.4 14 11 14 15.2 12 20 10 28 8 46 4

1 2 ⁄ 1 2 ⁄ 1 2 ⁄ 1 ⁄ 2 3 4 ⁄ 3 4 ⁄ 1 1 ⁄ 4

25 30 35 45 60 90 150

3.5 4.7 5.5 7.6 10 14 23 34 43

230 Volts 1 14 2 ⁄ 1 14 2 ⁄ 1 14 2 ⁄ 1 14 ⁄ 2 1 14 2 ⁄ 1 12 2 ⁄ 3 8 4 ⁄ 6 1 1 5 1 ⁄ 4

15 15 20 25 30 45 70 110 125

Where high ambient temperature is present, it may, in some cases, be necessary to install next larger size thermal overload relay.

3-Phase Squirrel-Cage Induction Motors 1 1 1 ⁄ 2 2 3 5 1 7 ⁄ 2 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300

230 Volts 3.3 14 4.7 14 6 14 9 14 15 12 22 8 27 8 38 6 52 4 64 3 77 1 101 00 125 000 149 200,000 C.M. 180 0000 245 ‡ 500 310 ‡ 750 360 ‡ 1000 480 580 696

1 2 ⁄ 1 2 ⁄ 1 ⁄ 2 1 2 ⁄ 1 ⁄ 2 3 4 ⁄ 3 ⁄ 4 1 1 ⁄ 4 1 1 ⁄ 4 1 1 ⁄ 4 1 1 ⁄ 2

2 2 1 2 ⁄ 2 1 2 ⁄ 2 3 1 3 ⁄ 2 4

* * * * *

15 15 20 30 45 = 60 = 70 = 80 =110 =150 =175 =200 =250 =300 =300 =500 =500 =600

1.7 2.4 3.0 4.5 7.5 11 14 19 26 32 39 51 63 75 90 123 155 180 240 290 348

460 Volts 1 14 2 ⁄ 1 14 2 ⁄ 1 14 ⁄ 2 1 14 2 ⁄ 1 14 ⁄ 2 1 14 2 ⁄ 1 12 ⁄ 2 3 10 4 ⁄ 3 8 ⁄ 4 1 6 1 ⁄ 4 1 6 1 ⁄ 4 1 4 1 ⁄ 4 1 3 1 ⁄ 4 1 0 000 0000 300 ‡ 500 ‡

1 1 ⁄ 2 2 2 1 2 ⁄ 2 1 2 ⁄ 2 3

* * * * *

15 15 15 15 25 = 30 = 35 = 50 = 70 = 70 = 80 =100 =125 =150 =200 =250 =350 =400 =500

205

MOTOR WIRING AT STANDARD SPEEDS, (Continued) From National Electrical Code ==Min.

HP.

**Max. ==Min. Full Size Size Rating Full Size Size Load Wire Conof Load Wire ConAmp. AWG duit Branch Amp. AWG duit Per Rubber in Circuit Per Rubber in Phase Covered Inches Fuses Phase Covered Inches

**Max Rating of Branch Circuit Fuses

DIRECT CURRENT MOTORS 1 1 1 ⁄ 2 2 3 5 1 7 ⁄ 2 10 15 20 25 30 40 50 60 75 100

8.4 12.5 16.1 23 40 58 75 112 140 184 220 292 360

115 Volts 1 14 ⁄ 2 1 12 ⁄ 2 3 10 ⁄ 4 3 8 ⁄ 4 6 1 1 3 1 ⁄ 4 1 1 1 ⁄ 2 00 2 000 2 1 300 ‡ 2 ⁄ 2 ‡ 400 3 1 700 ‡ 3 ⁄ 2 ‡ 1000 4

15 20 25 35 60 90 125 175 225 300 350 450 600

230 Volts 1 4.2 14 ⁄ 2 1 6.3 14 ⁄ 2 1 8.3 14 ⁄ 2 1 12.3 12 ⁄ 2 3 19.8 10 ⁄ 4 28.7 6 1 38 6 1 1 56 4 1 ⁄ 4 1 74 1 1 ⁄ 2 92 0 2 110 00 2 1 146 0000 2 ⁄ 2 1 ‡ 180 300 2 ⁄ 2 215 400 ‡ 3 1 268 600 ‡ 3 ⁄ 2 ‡ 355 1000 4

15 15 15 20 30 45 60 90 125 150 175 225 300 350 450 600

‡ M.C.M. == In order to avoid excessive voltage drop where long runs are involved, it may be necessary to use conductors and conduit of sizes larger than the minimum sizes listed above. ** Branch-circuit fuses must be large enough to carry the starting current, hence they protect against short-circuit only. Additional protection of an approved type must be provided to protect each motor against normal operating overloads. * For full-voltage starting of normal torque, normal starting current motor. = For reduced-voltage starting of normal torque, normal starting current motor, and for full-voltage starting of high-reactance, low starting current squirrel-cage motors.

NEMA Frame Numbers for Polyphase Induction Motors “T” Frame

206

Horsepower 2 3 5 1 7 ⁄ 2 10

1800 RPM 145T 182T 184T 213T 215T

1200 RPM 184T 213T 215T 254T 256T

15 20 25 30 40

254T 256T 284T 286T 324T

284T 286T 324T 326T 364T

50 60 75

326R 364T 365T

365T 404T 405T

DIMENSIONS, IN INCHES, OF ELECTRIC MOTORS By NEMA Frame Number M+N

D

E

F

U

V

Keyway

182T

3 7 ⁄ 4

1 4 ⁄ 2

3 3 ⁄ 4

1 2 ⁄ 4

1 1 ⁄ 8

1 2 ⁄ 2

184T

1 8 ⁄ 4

1 4 ⁄ 2

3 3 ⁄ 4

3 2 ⁄ 4

1 1 ⁄ 8

1 2 ⁄ 2

213

1 9 ⁄ 4

1 5 ⁄ 4

1 4 ⁄ 4

3 2 ⁄ 4

1 1 ⁄ 8

3 2 ⁄ 4

213T

5 9 ⁄ 8

1 5 ⁄ 4

1 4 ⁄ 4

3 2 ⁄ 4

3 1 ⁄ 8

1 3 ⁄ 8

215

10

1 5 ⁄ 4

1 4 ⁄ 4

1 3 ⁄ 2

1 1 ⁄ 8

3 2 ⁄ 4

215T

3 10 ⁄ 8

1 5 ⁄ 4

1 4 ⁄ 4

1 3 ⁄ 2

13 ⁄ 8

31 ⁄ 8

254T

3 12 ⁄ 8

1 6 ⁄ 4

5

1 4 ⁄ 8

15 ⁄ 8

3 3 ⁄ 4

254U

1 12 ⁄ 8

1 6 ⁄ 4

5

1 4 ⁄ 8

13 ⁄ 8

31 ⁄ 2

256T

1 13 ⁄ 4

1 6 ⁄ 4

5

5

15 ⁄ 8

3 3 ⁄ 4

256U

13

1 6 ⁄ 4

5

5

13 ⁄ 8

31 ⁄ 2

284T

1 14 ⁄ 8

7

1 5 ⁄ 2

43 ⁄ 4

17 ⁄ 8

3 4 ⁄ 8

284U

3 14 ⁄ 8

7

1 5 ⁄ 2

43 ⁄ 4

15 ⁄ 8

45 ⁄ 8

286T

7 14 ⁄ 8

7

1 5 ⁄ 2

1 5 ⁄ 2

17 ⁄ 8

3 4 ⁄ 8

286U

1 15 ⁄ 8

7

1 5 ⁄ 2

1 5 ⁄ 2

15 ⁄ 8

45 ⁄ 8

324T

3 15 ⁄ 4

8

1 6 ⁄ 4

1 5 ⁄ 4

1 2 ⁄ 8

5

324U

1 16 ⁄ 8

8

1 6 ⁄ 4

1 5 ⁄ 4

17 ⁄ 8

53 ⁄ 8

326T

1 16 ⁄ 2

8

1 6 ⁄ 4

6

1 2 ⁄ 8

5

326U

7 16 ⁄ 8

8

1 6 ⁄ 4

6

17 ⁄ 8

3 5 ⁄ 8

364T

3 17 ⁄ 8

9

7

55 ⁄ 8

23 ⁄ 8

55 ⁄ 8

364U

7 17 ⁄ 8

9

7

55 ⁄ 8

1 2 ⁄ 8

61 ⁄ 8

365T

7 17 ⁄ 8

9

7

1 6 ⁄ 8

23 ⁄ 8

55 ⁄ 8

365U

3 18 ⁄ 8

9

7

1 6 ⁄ 8

1 2 ⁄ 8

61 ⁄ 8

404T

20

10

8

1 6 ⁄ 8

27 ⁄ 8

7

404U

7 19 ⁄ 8

10

8

1 6 ⁄ 8

23 ⁄ 8

67 ⁄ 8

405T

3 20 ⁄ 4

10

8

67 ⁄ 8

27 ⁄ 8

7

405U

5 20 ⁄ 8

10

8

67 ⁄ 8

23 ⁄ 8

67 ⁄ 8

444U

3 23 ⁄ 8

11

9

1 7 ⁄ 4

27 ⁄ 8

3 8 ⁄ 8

445U

3 24 ⁄ 8

11

9

1 8 ⁄ 4

27 ⁄ 8

3 8 ⁄ 8

1 x 1 ⁄ ⁄ 8 4 1 x 1 ⁄ ⁄ 8 4 1 x 1 ⁄ ⁄ 8 4 5 ⁄ 16 x 5 ⁄ 32 1 x 1 ⁄ ⁄ 8 4 5 ⁄ 16 x 5 ⁄ 32 3 x 3 ⁄ 8 ⁄ 16 5 ⁄ 16 x 5 ⁄ 32 3 x 3 ⁄ 8 ⁄ 16 5 ⁄ 16 x 5 ⁄ 32 1 x 1 ⁄ ⁄ 4 2 3 x 3 ⁄ 8 ⁄ 16 1 x 1 ⁄ ⁄ 4 2 3 x 3 ⁄ 8 ⁄ 16 1 x 1 ⁄ ⁄ 4 2 1 x 1 ⁄ ⁄ 4 2 1 x 1 ⁄ ⁄ 4 2 1 x 1 ⁄ ⁄ 4 2 5 x 5 ⁄ 8 ⁄ 16 1 x 1 ⁄ ⁄ 4 2 5 x 5 ⁄ 8 ⁄ 16 1 x 1 ⁄ ⁄ 4 2 3 x 3 ⁄ 4 ⁄ 8 5 x 5 ⁄ 8 ⁄ 16 3 x 3 ⁄ 4 ⁄ 8 5 x 5 ⁄ 8 ⁄ 16 3 x 3 ⁄ 4 ⁄ 8 3 x 3 ⁄ 4 ⁄ 8

207

S E L B A C E L B A T R O P E H T R O F S E Z I S R E T E M A I D E L B A C D N A S E I T I C A P A C G N I Y R R A C T N E R R U C

208

” r e ) s t W e e “ h m c e i a I n p ( y D

T r o t c y u * t i d p c n m a o A p a C C 4 ” G “ e p y T r o t c u d n o C 3

r ) e s t e e h m c a I n i ( D

6 7 3 9 8 8 4 7 0 9 2 . 0 . 9 . 7 . 6 . 4 . 3 . 2 . 1 . 9 . 2 2 1 1 1 1 1 1 1 0

0 0 0 5 5 0 5 5 0 0 1 9 7 4 2 1 9 8 6 5 2 1 1 1 1 1

9 4 9 5 5 1 4 4 7 1 1 3 . 0 . 8 . 7 . 6 . 5 . 3 . 2 . 1 . 0 . 9 . 2 2 1 1 1 1 1 1 1 1 0

y t i p c 5 5 0 0 0 5 0 0 5 5 5 7 4 2 9 6 4 3 1 9 7 5 m a p A a 2 2 2 1 1 1 1 1 C

. d n o C 4

) s e h . c d n I ( n o r d C r t o e e 3 C m a O i S D e . p d y n o T C 2

0 0 5 5 5 5 7 0 8 3 7 . 6 . 6 . 4 . 4 .

0 0 0 0 5 9 4 6 3 0 6 . 6 . 5 . 4 . 4 .

s a d e s u r o t c u d n o c h t 4 h t i w t i u . c e r l i c b a e c s ” a h G p “ 3 e p y n t o r o e t l b c u a c d ” n o c W “ 3 e r p o y f t y r t i o t c c u a d p n a c o c p 4 m g a n e i s s u u , n d e n h u o r W * g

0 5 0 5 0 4 0 3 0 9 6 . 6 . 5 . 4 . 3 .

e l d b a e t C a d l y t u e s i f p i c i n t 5 0 5 0 7 I r m a 2 2 1 1 e A p n a r C C e 6 t s 6 e o W c m n o r o r f B M o C a f G e t 0 0 0 0 0 2 4 6 8 z M / / / / 1 2 3 4 6 8 1 1 1 1 1 a r i W . 4 3 2 1 D o A S 0 5 C e 2 v e o r b i A W

GENERATOR SIZE TO POWER ELECTRIC MOTORS ON CRUSHING AND SCREENING PLANTS The minimum generator size to power a group of motors should be selected on the basis of the following rules, which allow all motors to operate simultaneously with complete freedom of starting sequence. A. GENERATOR KW—0.8 x total electric name plate horsepower. B. GENERATOR KW—2 x name plate horsepower of the largest electric motor with across-the-line starter. C. GENERATOR KW—1.5 x name plate horsepower of the largest electric motor with reduced voltage starting (with 80 percent starting voltage). D. GENERATOR KW—2.25 x name plate horsepower of the largest electric motor with part winding starting. For across-the-line starting, use the larger of the two values determined from A and B. For reduced voltage starting, use the larger of the two values determined from A and C. For part winding starting, use the larger of the two values determined from A and D. For combinations of the above starting types, use the largest value determined from A, B, C, and D as they apply.

209

DREDGE PUMP SIZE

SLURRY GPM

TPH

4

680

38

6

1,500

85

8

2,700

153

10

4,100

233

12

5,900

335

14

7,300

414

16

9,670

550

18

12,280

696

20

15,270

866

20% Solids @ 100 lb./cu. ft. (% Solids by Weight) NOTE: GPM ÷ 17.6 = TPH TPH X 17.6 = GPM Above information can be used as a guide in preliminary selection of material handling components. For plants charged by dredge pumps, proper selection of sand processing components is in part controlled by maximum amount of water in the slurry. Prior to final selection of machinery, complete information must be assimilated so sound judgement can be exercised.

210

VELOCITY OF FLOW IN PIPES VELOCITY OF FLOW IN PIPES 3

4

5

6

7

VELOCITY - FEET PER SECOND 8 9 10 11 12

13

14

15

16

17

12" 4000

4000 10"

3000

3000

2500

2500 8"

2000

2000

1500

1500 6"

1000 900 800

1000 900 800

5"

700

700

E 600 T U N 500 I M R 400 E P S 300 N O L L A G200 . S . U 150

600 4"

500 400

3"

300

2-1/2"

200

150

2"

100 90 80

E T U N I M R E P S N O L L A G . S . U

100 90 80

1-1/2"

70

70 1-1/4"

60

60

50

50

40

40 1"

30

30

STD

25

25

PIPE SIZE

20 3

4

5

6

7

8 9 10 11 12 VELOCITY - FEET PER SECOND

20 13

14

15

16

17

NOTE: Based on following ID’s for Std. Wt. W:I or Steel Pipe

1” 1¼” 1½” 2”

1.049” 1.380” 1.610” 2.067”

2½” 3” 4” 5”

2.469” 3.068” 4.026” 5.047”

6” 8” 10” 12”

6.065” 7.981” 10.020” 11.938”

211

FRICTION LOSS IN PIPES .1

.2

FRICTION LOSS FOR WATER IN FEET OF HEAD PER 100 FT. PIPE .3 . 4 .5 .6 .8 1.0 2 3 4 5 6 8 10 20

30

40 50

5000

5000

4000

4000

3000

3000

2000

2000

1000

1000

" 1 2

1000 800 700 E600 T U500 N I M400 R E300 P

1000 800 700 600 E T 500 U N I 400 M R 300 E P S N 200 O L L 100 A G . S . 100 U

" 1 0 8 "

6 "

S N O200 L L A100 G . S . U100

5 "

4 "

80 70 60

80 70 60

3 "

50

50

" 1 / 2 2 -

40 30

40 30

2 "

20

20

" 1 / 2 1 " 1 / 4 1 -

1 "

10

10 .1

.2

.3

.4

.5 .6

.8 1.0

2

3

4

5 6

8

10

20

30

FRICTION LOSS FOR WATER IN FEET OF HEAD PER 100 FT. PIPE

NOTE: Based on new, Standard Weight Wrought Iron or Steel Pipe.

212

40 50

FLOW OVER WEIRS Settling Tanks, Classifiers, Sand Preps, Flumes Settling Tanks, Classifiers, Sand Preps, Flumes 5

25

GPM OVERFLOW PER FOOT OF WEIR 50 75 100 150 200 250

300

S4 E H C N I N I ) 3 H ( H T P E D 2 W O L F R E V O1

0

400 5

4 S

E H C N I N I 3 ) H ( H T P E D 2 W O L F R E V 1 O

25

50

75 100 150 200 250 GPM OVERFLOW PER FOOT OF WEIR

300

0 400

GENERAL Measure overflow depth (h) at a distance back of weir at least four times h. Use a flat strip taped to the end of a carpenter’s level.

Multiply figure from curve by length of weir. FLUME OR LAUNDER Use a bevel-edge steel plate or board with sharp edge upstream.

L(Weir length) and D (depth of water behind weir) must each be at least three times h. Water or slurry must fall free of weir; i.e., with air space underneath. If possible, drill air holes in side of launder on downstream side of weir plate. Curve does not apply to triangular or notched weirs.

213

SPRAY PIPE DESIGN AMOUNT OF WATER REQUIRED TO WASH ROCK As a guideline use (5 to 10 gallons/minute) per (yard/hour) or for 100 pound per cubic foot rock. As a guideline use (3.7 to 7.4 gallons/minute) per (ton/hour). Example: (200 ton/hour) x (3.7 gallons/ minute) per (ton/hour) = 740 gallons/minute Nozzle Spray Pipe Dual Flat Spray Pattern Standard Orifice Size 1/4”

TOP

CTR

BT

TOTAL PIPES PER SCREEN

8203-38LP

6

6

5

17

425

3017

3655

4250

8202-38LP

6

-

5

11

275

1952

2365

2750

7203-38LP

6

6

5

17

374

2655

3216

3740

7202-38LP

6

-

5

11

242

1718

2081

2420

6203-32LP

6

6

5

17

323

2293

2778

3230

6202-32LP

6

-

5

11

209

1484

1797

2090

6163-32LP

5

5

4

14

266

1889

2288

2660

6162-32LP

5

-

4

9

171

1214

1471

1710

5163-32LP

5

5

4

14

210

1491

1806

2100

5162-32LP

5

-

4

9

135

959

1161

1350

5143-32LP

4

4

4

12

180

1278

1548

1800

5142-32LP

4

-

4

8

120

852

1032

1200

PIPES/DECK SCREEN MODEL

TOTAL NOZZLES PER SCREEN

GAL. PER GAL. PER GAL. PER SCREEN SCREEN SCREEN AT 20 PSI AT 30 PSI AT 40 PSI 1 1 1 4” ORIFICE ⁄ 4” ORIFICE ⁄ 4” ORIFICE ⁄

1 4” STANDARD NOZZLE ORIFICE SIZE ⁄ 20 PSI at Nozzle capacity is 7.1 gallons per minute 30 PSI at Nozzle capacity is 8.6 gallons perminute 40 PSI at Nozzle capacity is 10 gallons per minute

8’ Spray Pipe has 25 Nozzles per pipe 7’ Spray Pipe has 22 Nozzles per pipe 6’ Spray Pipe has 19 Nozzles per pipe 5’ Spray Pipe has 15 Nozzles per pipe

SPLASH SPRAY PIPES Splash Spray Pipe Single Flat Splash Pattern 3/16” Diameter Holes on 2” Centers

Approximately the same capacity as Nozzle Spray Pipes Shown above.

214

SPRAY NOZZLES FOR VIBRATING SCREENS The introduction of water under pressure over the vibrating screens often greatly improves screening efficiency as well as aids in the removal of deleterious materials on the individual aggregate particles. We utilize Type WF Flat Spray Nozzles over the screens to produce a uniform, flat spray pattern without hard edges at pressures of 5 psi and up. Tapered edges of the spray pattern permits pattern overlap with even distribution of the spray. The impact of spray is generally greater with narrower spray angles, assuming the same flow rate.

AVAILABLE SPRAY ANGLES Nozzle Size

0° 15° 25° 40° 50° 65° 80° 90°

— — — — — — — —

All sizes All sizes thru WF 150 All sizes thru WF 150 All sizes thru WF 150 All sizes thru WR 200 All sizes All sizes All sizes thru WF 250

215

0 0 5 5 5 0 . 0 . 2 . 2 . 8 . 0 . 3 . 3 . 0 . 2 . 4 . 0 . 0 1 2 2 2 3 3 4 4 5 1

9 0 8 8 5 7 5 0 . 0 . 2 . 2 . 2 . 9 . 1 . 6 . 8 . 0 . 4 . 8 . 1 2 2 2 3 3 3 4 4 0 8 7 1 3 5 7 9 4 6 8 2 0 . 9 . . . . . . . . . . 7 . 1 1 2 2 2 2 2 3 3 3 4 0 7 0 7 5 7 5 . 6 . 1 . 9 . 1 . 3 . 2 . 2 . 1 . 3 . 3 . 9 . 6 7 1 1 2 2 3 3 3

I S T P 0 R A 4 t H C a y t i Y c T a I p C a A C P — A r C b e F m W u N E P e l Y z T z o N

1 E 0 4 5 8 9 1 3 5 8 0 2 5 0 . . . . . . . . . . . . R 5 7 1 1 1 1 2 2 2 2 3 3 3 U S S E 3 R 0 6 3 4 6 7 9 1 2 5 7 8 2 P 0 . 1 . 1 . 1 . 1 . 2 . 2 . 2 . 2 . 2 . 3 . 4 . 1 I S P T 5 A 0 5 1 4 5 6 8 9 2 3 5 7 0 . 2 . . . . . . . . . . 3 . 1 M 1 1 1 1 1 1 2 2 2 2 P G 5 9 0 — 4 5 0 . 0 . 1 . 2 . 3 . 1 . 6 . 8 . 9 . 0 . 2 . 2 . 8 Y 1 1 1 1 1 1 1 2 2 T I C A 0 9 7 7 7 P 7 8 9 1 2 3 4 5 6 7 9 5 3 . . . . . . . . . . . . A 1 1 1 1 1 1 1 1 1 C 2 3 1 9 7 9 5 0 1 3 3 4 6 0 0 3 6 7 7 8 . . . . . . 1 . 1 . 1 . 1 . 1 . 1 . 1 8 0 . 8 2

7 4 1 8 5 2 9 5 6 7 7 8 9 . . . . . . 9 . 1 . 2 . 3 . 4 . 1 1 1 1

4 9 0 2 . 6 . 4

5 1 7 3 0 6 8 5 6 6 7 8 8 . . . . . . 9 . 1 . 1 . 2 . 1 1 1

0 0 5 0 0 2 4 4 . . . 5 . 4

5 0 6 5 0 0 5 0 5 . 6 . . 7 . 8 . 8 . 9 . 0 . 1

⁄

4 3

⁄

2 1

E Z I S 3 8 ⁄ E P I P

⁄

4 1

⁄

8 1

. . . 4 2 5 7 0 2 4 7 2 4 6 0 v f i a 3 5 5 5 6 6 6 6 7 7 7 8 i u r i 0 D q . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . E O . 5 5 5 o . . . 9 0 R N 2 4 4 5 5 6 6 7 8 8 E E L 1 B Z Z M e O U l M M M M M M M M M M M M N N a F F F F F F F F F F F F M W W W W W W W W W W W W

216

. S E Z I S E L B A L I A V A T S O M E T A C I D N I S N M U L O C D E D A H S

3 . 1 . 6 . 2 . 7 . 2 . 8 . 3 . 3 . 1 . 8 . 4 . 0 . 0 . 0 7 4 3 0 8 6 5 7 0 4 1 8 5 1 0 5 1 1 1 2 2 2 3 5 7 8 0 4

I S P 0 4 t a y t i c a p a C — r e b m u N e l z z o N

1 1 7 3 5 7 8 0 2 3 6 4 3 0 8 0 . . . . . . . . . . . . . . 0 4 6 9 2 5 9 2 5 1 7 3 9 4 7 0 4 1 1 1 2 2 3 4 6 7 9 2 1 1 5 2 0 7 4 2 9 4 1 7 4 1 0 0 . . . . . . . . . . . . . . 0 4 5 8 1 3 6 9 1 7 1 4 8 2 0 3 1 1 1 1 2 2 4 5 6 8 1 1 0 4 5 7 5 5 0 . 4 . 6 . 0 . 2 . 4 . 7 . 9 . 3 . 3 . 3 . 8 . 9 . 9 . 2 3 9 1 3 5 7 2 4 5 6 1 1 1 1 2 3 4 5 6 8 E 0 7 5 7 . 9 . 8 . 7 . 9 . 6 . 3 . 4 . 4 . 0 . 8 . 4 . 0 . 4 . 5 9 R 1 2 3 5 7 1 5 9 9 8 8 7 U 1 1 1 1 2 3 4 5 7 S S E 4 7 5 7 R 0 . 2 . 4 . 3 . 9 . 9 . 1 . 6 . 8 . 3 . 6 . 4 . 4 . 2 . P 0 2 3 6 7 1 2 5 1 9 7 3 1 I 1 1 1 2 3 3 4 6 S P T 8 2 7 1 5 9 4 1 2 3 4 4 6 A 0 1 . . . . . . . . . . . . . . 8 2 2 4 5 7 8 9 1 4 1 8 5 2 6 M 1 1 2 2 3 4 5 P G 8 5 7 9 1 3 6 8 2 4 5 5 8 0 0 — . . . . . . . . . . . . . . 6 1 2 3 4 6 7 8 9 2 8 4 0 6 9 Y 1 1 2 3 3 4 T I C A 5 P . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 A 4 5 7 5 0 5 0 1 2 3 4 6 8 0 0 C 1 1 2 2 3 4 3 7 5 0 . 1 . 6 . 3 . 3 . 2 . 1 . 8 . 6 . 0 . 3 . 6 . 0 . 6 . 3 1 2 4 5 6 5 8 3 7 1 6 4 1 1 2 2 3 1 1 8 5 2 9 6 1 6 1 7 2 2 0 . . . . . . . 4 . . . . . . . 2 1 1 2 2 3 4 4 5 7 0 4 7 1 8 1 1 1 2 2 2 9 2 5 7 5 . 8 . 2 . 1 . 3 . 3 . 0 . 1 . 2 . 2 . 7 . 4 . 4 . 1 . 1 1 3 4 5 6 9 2 5 8 4 1 1 1 2 5 7 0 5 5 5 5 0 . 1 . 0 . 2 . 0 . 3 . 0 . 0 . 5 . 0 . 2 . 0 . 2 . 1 . 1 2 3 4 5 7 0 5 0 1 1 1 2 4 ⁄ 3

. S E Z I S — E L T B R A L A I A H V C A T Y S T I O C M A E 2 ⁄ T 1 P A A C E I Z C I D S 3 8 ⁄ N F E I P I S W P N 4 ⁄ E 1 M P U L Y O T 8 ⁄ C 1 D E . . D . a 2 4 4 2 4 v f 4 4 2 4 4 6 2 i 6 6 4 6 3 6 6 2 i ⁄ ⁄ ⁄ ⁄ ⁄ ⁄ ⁄ ⁄ 3 6 6 3 1 3 A i ⁄ ⁄ u 1 5 2 7 1 r D ⁄ 3 ⁄ 7 ⁄ 9 ⁄ 5 1 3 3 7 1 9 1 1 1 1 2 q H E O S . 0 0 0 0 0 0 o 5 0 0 0 0 0 0 0 0 5 0 5 0 R N E 1 2 3 4 5 6 7 8 1 1 2 2 3 0 4 E L B Z Z M e * O U l M M M M M M * M M M M M M M N N a F F F F F F M F F F F F F F F M W W W W W W W W W W W W W W

217

DIMENSIONS AND WEIGHTS FOR TYPE WF DIMENSIONS (Inches) PIPE SIZE

B

C

WEIGHT (Ounces)

TYPE

1 ⁄ 8

WFM

11

7 ⁄ 16

5 ⁄ 16

.4

1 4 ⁄

WFM

31

⁄ 32

9 16 ⁄

3 8 ⁄

.7

3 8 ⁄

WFM

1

11

⁄ 16

7 16 ⁄

1.1

1 2 ⁄

WFM

117 ⁄ 64

7 8 ⁄

1 2 ⁄

2.5

3 4 ⁄

WFM

127 ⁄ 64

5 8 ⁄

5.0

A

⁄ 16

11

⁄ 16

WATER VOLUME REQUIRED FOR WASHING AGGREGATES

The amount of water required for washing aggregates under average conditions is 3 to 5 GPM of water for each TPH of material fed to a washing screen. The finer the feed gradation, the more GPM of water required. GETTING MAXIMUM WASHED PRODUCT FROM A VIBRATING SCREEN

Screen efficiency can be greatly increased by applying water directly to the feed box located ahead of the vibrating screen. Water volume applied must be sufficient to form a slurry in the feed box so that effective screening begins immediately when the wet product contacts the screen.

218

WEIGHTS AND MEASURES—UNITED STATES Linear Measure

1 mile

1 furlough 1 station

{

=

{

=

{

=

8 furlongs 80 chains 320 rods 1760 yards 5280 feet 10 chains 220 yards 6.06 rods 33.3 yards 100 feet

1 chain

=

1 rod

=

1 yard 1 foot

= =

{ { {

4 rods 22 yards 66 feet 100 links 5.5 yards 16.5 feet 3 feet 36 inches 12 inches

Gunter’s or Surveyor’s Chain Measure 1 link = 7.92 inches 1 statute mile = 80 chains

1 chain

=

{

100 links 4 rods 66 feet 22 yards

{ {

1 272 ⁄ 4 sq. feet 1 30 ⁄ 4 sq. yards 1,296 sq. inches 9 sq. feet 144 sq. inches

Land Measure 1 township

=

1 sq. mile

=

1 acre

=

{ {

{

36 sections 36 sq. miles 1 section 640 acres 4,840 sq. yards 43,560 sq. feet 160 sq. rods

1 sq. rod

=

1 sq. yard 1 sq. foot

= =

Cubic Measure 1 cubic yard = 1 cord (wood) = 1 ton (shipping) =

27 cubic feet 4x4x8 ft. = 128 cu. ft. 40 cubic ft.

1 cu. ft. = 1 bushel = 1 gallon =

1728 cu. in. 2150.42 cu. in. 231 cu. in.

Weights (Commercial) 1 long ton = 2250 lbs. 1 short ton = 2000 lbs.

1 pound = 16 ounces 1 ounce = 16 drams

Troy Weight (For Gold and Silver) 1 pound

=

{

12 ounces 5760 grains

1 ounce

=

{

20 pennyweights 480 grains

{

63 gallons 311/2 gallons 7.48 U.S. gals. 1728 cu. in. 1 62 ⁄ 2 lbs. @ 62°F

1 pennyweight = 24 grains

Liquid Measure = 1 pint (pt.) = = 1 quart (qt.) =

{ {

1 gallon (gal.) =

{

4 gills (gl.) 28.875 cu. in. 2 pints 57.75 cu. in. 4 quarts 8 pints 32 gills 231 cu. in. 1 8 ⁄ 2 lbs. @ 62°F

1 hogshead 1 barrel 1 cu. ft. water

= = =

219

WEIGHTS AND MEASURES—UNITED STATES Dry Measure (When necessary to distinguish the dry pint or quart from the liquid pint or quart, the word “dry” should be used in combination with the name or abbreviation of the dry unit.) 1 quart (qt.) 1 peck (pk.)

pints (pt.) { 267.20 cu. in.

=

{

=

1 bushel (bu. )

=

8 quarts 16 pints 537.605 cu. in.

{

4 pecks 32 quarts 2150.42 cu. in.

Mariner’s Measure 1 fathom 1 cable length 1 nautical mile

= = =

6 feet 120 fathoms 6,080 feet

1 marine league = 1 statute mile

=

3 marine miles 1 2 cable lengths 7 ⁄ 5,280 feet

{

Measures of Power 1 BTU per minute

=

1 ft. lb. per minute

=

1 horsepower

=

1 watt

=

1 kilowatt

=

.0236 17.6 .0176 778 .0226 .001285 746 .746 33,000 42.4 .00134 .001 44.2 .0568 1.341 1000 44.250 56.8

{ {

{ { {

horsepower watts kilowatts foot lbs. per min. watts BTU per min. watts kilowatts ft. lbs. per min. BTU per min. horsepower kilowatts ft. lbs. per min. BTU per min. horsepower watts ft. lbs. per min. BTU per min.

WEIGHTS AND MEASURES—METRIC Area Measure 1 sq. centimeter = (cm2) 1 sq. meter (m2) =

{

100 sq. millimeters (mm2) 1,000,000 mm2 10,000 cm2

1 are (a)

=

1 hectare (ha) 1 sq. kilometer (km2)

= =

{ {

100 m2 10,000 m2 100 a 1,000,000 m 2 100 ha

Linear Measure 1 centimeter (cm) =

{ = {

1 decimeter (dm) = 1 meter (m)

10 millimeters (mm) 100 mm 10 cm 1,000 mm 10 dm

1 dekameter (dkm)

=

1 hectometer (hm)

=

1 kilometer (km)

=

{ {

10 m 100 m 10 dkm 1,000 m 10 hm

Weight 1 centigram (cg) =

{ = {

1 decigram (dg) = 1 gram (g)

220

10 milligrams (mg) 100 mg 10 cg 1,000 mg 10 dg.

1 hectogram (hg) 1 dekagram (dkg)

= =

1 kilogram (kg) 1 metric ton (1)

= =

{ {

100g 10 dkg 10 g 1,000 g 10 hg 1,000 kg

WEIGHTS AND MEASURES—METRIC (Continued) Cubic Measure 1 cubic centimeter (cm3)

=

1 cubic decimeter (dm3)

=

1 cubic meter (m3)

=

{

1,000 cubic millimeters (mm3) 1,000,000 mm3 1,000 cm3

{

1 stere 1,000,000,000 mm3 1,000,000 cm3 1,000 dm3

Volume Measure 1 centiliter (cl)

=

1 deciliter (dl)

=

1 liter* (l)

{ = {

10 milliliters (ml) 100 ml 10 cl 1,000 ml 10 dl

1 dekaliter (dkl) = 1 hectoliter (hl) 1 kiloliter (kl)

{ = { =

10 l 100 l 10 dkl 1,000 l 10 hl

*The liter is defined as the volume occupied, under standard conditions, by a quantity of pure water having a mass of 1 kilogram.

Power 1 metric horsepower

=

{

.986 U.S. horsepower 736 watts .736 kilowatts

32,550 ft. lbs. per min. 41.8 BTU per min.

METRIC-U.S. CONVERSION FACTORS (Based on National Bureau of Standards) Area Sq. cm. Sq. m. Ares Sq. m Hectare Sq. km

x 0.1550 x 10.7639 x 1076.39 x 1.1960 x 2.4710 x 0.3861

= sq. ins. = sq. ft. = sq. ft. = sq. yds. = acres = sq. miles

Sq. ins. Sq. ft. Sq. ft. Sq. yds. Acre Sq. miles

x 6.4516 x 0.0929 x 0.00093 x 0.8361 x 0.4047 x 2.5900

= sq. cm = sq. m = ares = sq. m = hectares = sq. km

Flow Cu. ft. per min. x 0.028314 = cu. m per min. Cu. m per min. x 35.3182 = cu. ft. per min.

Length Centimeters Meters Meters Kilometers Kilometers

x 0.3937 x 3.2808 x 1.0936 x 0.6214 x 0.53959 *Statute miles

= inches = feet = yards = miles* = miles**

Inches Feet Yards Miles* Miles**

x 2.5400 = centimeters x 0.3048 = meters x 0.9144 = meters x 1.6093 = kilometers x 1.85325 = kilometers **Nautical miles

Power Metric horsepower x .98632 = U.S. horsepower U.S. horsepower x 1.01387 = metric horsepower

Pressure Kgs per sq. cm Lbs. per sq. in. Kgs per sq. in. Kgs per sq. m Lbs. per sq. ft. Kgs per sq. m

x 14.223 x 0.0703 x 0.2048 x .204817 x 4.8824 x .00009144

= lbs. per sq. in. = kgs per sq. cm = lbs. per sq. ft. = lbs. per sq. ft. = kgs per sq. m = tons (long) per sq. ft.

221

METRIC-U.S. CONVERSION FACTORS Pressure (Continued) Tons (long) per sq. ft. Kgs per sq. mm Tons (long) per sq. in. Kgs per cu. m Lbs. per cu. ft Kgs per m Lbs. per ft. Kg/m Ft. lbs. Kgs per sq. com Normal atmosphere

x 10940.0 x .634973 x 1.57494 x .062428 x 16.0184 x .671972 x 1.48816 x 7.233 x .13826 x 0.9678 x 1.0332

(Continued)

= kg per sq. m = tons (long) per sq. in. = kg per sq. mm = lbs. per cu. ft. = kgs per cu. m = lbs. per ft. = kgs per m = ft. lbs. = kg/m = normal atmosphere = kgs per sq cm

Weight Grams Grams Grams Kgs Kgs Kgs Tons* Tons*

x 15.4324 x 0.0353 x 0.0022 x 2.2046 x 0.0011 x 0.00098 x 1.1023 x 2204.62

= grains = oz. = lbs. = lbs. = tons (short) = tons (long) = ton (short) = lbs.

Grains Oz. Lbs. Lbs. Lbs. Tons (short) Tons (short) Tons (long)

x 0.0648 x 28.3495 x 453.592 x 0.4536 x 0.0004536 x 907.1848 x 0.9072 x 1016.05

=g =g =g = kg = tons* = kg = tons* = kg

Volume Cu. cm. Cu. m Cu. m Liters Liters Liters Liters

x 0.0610 x 35.3145 x 1.3079 x 61.0250 x 0.0353 x 0.2642 x 0.0284

= cu. in. = cu. ft. = cu. yds. = cu. in. = cu. ft. = gals. (U.S.) = bushels (U.S.)

Liters x

{

Cu. ins. Cu. ft. Cu. yds. Cu. ins. Cu. ft. Gallons Bushels

x 16.3872 x 0.0283 x 0.7646 x 0.0164 x 27.3162 x 3.7853 x 35.2383

= cu. cm = cu. m = cu. m = liters = liters = liters = liters

1000.027 = cu. cm 1.0567 = qt. (liquid) or 0.9081 = qt. (dry) 2.2046 = lb. of pure water at 4°C = 1 kg.

Miscellaneous Conversion Factors

222

Board feet x 144 sq. in. x 1 in. = cubic inches Board feet x .0833 = cubic feet Cubic feet x 6.22905 = gallons, Br. Imp. Cubic feet x 2.38095 x 10- 2 = tons, Br. shipping Cubic feet x .025 = tons, U.S. shipping Degrees, angular x .0174533 = radians Degrees, F. (less 32°F) x .5556 = degrees, Centigrade Degrees, centigrade x 1.8 plus 32 = degrees, F. Gallons, Br. Imp. x .160538 = cubic feet Gallons, Br. Imp. x 4.54596 = liters Gallons, U.S. x .13368 = cubic feet Gallons, U.S. x 3.78543 = liters Liters x .219975 = gallons, Br. Imp. Miles, statute x .8684 = miles, nautical Miles, nautical x 1.1516 = miles, statute Radians x 57.29578 = degrees, angular Tons, long x 1.120 = tons, short Tons, short x .892857 = tons, long Tons, Br. shipping x 42.00 = cubic feet Tons, Br. shipping x .952381 = tons, U.S. shipping Tons, U.S. shipping x 40.00 = cubic feet Tons, U.S. shipping x 1.050 = tons, Br. shipping Note: Br. Imp = British Imperial

APPROXIMATE WEIGHT OF MATERIALS MATERIAL Andesite, Solid . . . . . . . . . . . . . . . . . . . . . . . Ashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basalt, Broken . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caliche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cement, Portland . . . . . . . . . . . . . . . . . . . . . 1 Mortar, Portland, 1:2 ⁄ 2 ................ Cinders, Blast Furnace . . . . . . . . . . . . . . . . . Coal, Ashes and Clinkers. . . . . . . . . . . . . . . Clay, Dry Excavated. . . . . . . . . . . . . . . . . . . . Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . Dry Lumps . . . . . . . . . . . . . . . . . . . . . . . . . Wet Lumps . . . . . . . . . . . . . . . . . . . . . . . . . Compact, Natural Bed . . . . . . . . . . . . . . . . . Clay and Gravel, Dry . . . . . . . . . . . . . . . . . . . Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concrete, Asphaltic . . . . . . . . . . . . . . . . . . . . Gravel or Conglomerate . . . . . . . . . . . . . . . Limestone with Portland Cement . . . . . . . . Coal, Anthracite, Natural Bed . . . . . . . . . . . . Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bituminous, Natural Bed . . . . . . . . . . . . . . . Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cullett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dolomite, Broken . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Earth, Loam, Dry Excavated . . . . . . . . . . . . . Moist Excavated . . . . . . . . . . . . . . . . . . . . . Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . Dense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft Loose Mud . . . . . . . . . . . . . . . . . . . . . Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gneiss, Broken . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Granite, Broken or Crushed. . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravel, Loose, Dry . . . . . . . . . . . . . . . . . . . . Pit Run, (Gravelled Sand) . . . . . . . . . . . . . . 1 Dry ⁄ 4 - 2” . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Wet ⁄ 2 - 2”. . . . . . . . . . . . . . . . . . . . . . . . . . Gravel, Sand & Clay, Stabilized, Loose . . . . . Compacted . . . . . . . . . . . . . . . . . . . . . . . . . Gypsum, Broken . . . . . . . . . . . . . . . . . . . . . . Crushed . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Halite (Rock Salt) Broken . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hematite, Broken . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limonite, Broken. . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limestone, Broken or Crushed . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetite, Broken . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marble, Broken . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marble Wet Excavated. . . . . . . . . . . . . . . . . . Mica, Broken . . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight, lbs./ft3 173 41 122 188 90 100 135 57 40 68 114 67 100 109 100 114 140 150 148 94 69 84 52 80-100 109 181 78 90 100 125 108 95 116 179 103 168 95 120 105 125 100 150 113 100 174 94 145 201 306 154 237 97 163 205 315 98 160 140 100 180

Weight, lbs./yd3 4,660 1,100 3,300 5,076 2,430 2,700 3,654 1,539 1,080 1,847 3,080 1,822 2,700 2,943 2,700 3,085 3,780 4,050 3,996 2,546 1,857 2,268 1,413 2,160-2,700 2,940 4,887 2,100 2,430 2,700 3,375 2,196 2,565 3,141 4,833 2,778 4,525 2,565 3,240 2,835 3,375 2,700 4,050 3,054 2,700 4,698 2,545 3,915 5,430 8,262 4,159 6,399 2,625 4,400 5,528 8,505 2,650 4,308 3,780 2,700 4,860

Weight, kg./m3 2,771 657 1954 3012 1442 1602 2162 913 641 1089 1826 1073 1602 1746 1602 1826 2243 2403 2371 1506 1105 1346 833 1281-1602 1746 2809 1249 1442 1602 2002 1730 1522 1858 2,867 1650 2691 1522 1922 1682 2002 1602 2403 1810 1602 2787 1506 2323 3220 4902 2467 3028 1554 2611 3,284 5046 1570 2563 2243 1602 2883

223

APPROXIMATE WEIGHT OF MATERIALS MATERIAL Mud, Fluid ...................................................... Packed ......................................................... Dry Close ..................................................... Peat, Dry ........................................................ Moist............................................................ Wet .............................................................. Phosphate Rock, Broken ................................ Pitch............................................................... Plaster............................................................ Porphyry, Broken ........................................... Solid............................................................. Sandstone, Broken ......................................... Solid............................................................. Sand, Dry Loose ............................................ Slightly Damp .............................................. Wet .............................................................. Wet Packed .................................................. Sand and Gravel, Dry ..................................... Wet .............................................................. Shale, Broken ................................................. Solid............................................................. Slag, Broken................................................... Solid............................................................. Slag, Screenings ............................................ 3 Slag, Crushed ( ⁄ 4”) ........................................ Slag, Furnace, Granulated .............................. Slate, Broken.................................................. Solid............................................................. Stone, Crushed .............................................. Taconite ......................................................... Talc, Broken ................................................... Solid............................................................. Tar ................................................................. Trap Rock, Broken ......................................... Solid.............................................................

Weight, lbs./ft3 108 119 80-110 25 50 70 110 71.7 53 103 159 94 145 100 120 130 130 108 125 99 167 110 132 92 74 60 104 168 100 150-200 109 168 71.6 109 180

Weight, lbs./yd3 2,916 3,200 2,160-32,970 675 1,350 1,890 2,970 1,936 1,431 2,790 4,293 2,550 3,915 2,700 3,240 3,500 3,510 2,916 3,375 2,665 4,500 2,970 3,564 2495 1,998 1,620 2,800 4,535 2,700 4,050-5,400 2,931 4,535 1,936 2,950 4,870

Weight, kg./m3 1730 1906 1282-1762 400 801 1121 1762 1148 848 1650 2547 1506 2323 1602 1922 2082 2082 1730 2022 1586 2675 1762 2114 1474 1185 961 1666 2,691 1602 2403-3204 1746 2691 1148 1746 2883

NOTE: The above weights may vary in accordance with moisture content, texture; etc. MISCELLANEOUS USEFUL INFORMATION Area of circle: Multiply square of diameter by .7854. Area of rectangle: Multiply length by breadth. 1 Area of triangle: Multiply base by ⁄ 2 perpendicular height. Area of ellipse: Multiply product of both diameters by .7854. 1 2 radius. Area of sector of circle: Multiply arc by ⁄ Area of segment of circle: Subtract area of triangle from area of sector of equal angle. Area of surface of cylinder: Area of both ends plus length by circumference. Area of surface of cone: Add area of base to circumference of base multiplied 1 2 slant height. by ⁄ Area of surface of sphere: Multiply diameter 2 by 3.1416. Circumference of circle: Multiply diameter by 3.1416. Cubic inches in ball or sphere: Multiply cube of diameter by .5236. 1 3 the altitude. Cubic contents of cone or pyramid: Multiply area of base by ⁄ Cubic contents of cylinder or pipe: Multiply area of one end by length. 1 Cubic contents of wedge: Multiply area of rectangular base by ⁄ 2 height. Diameter of circle: Multiply circumference by .31831.

224

APPROXIMATE WEIGHTS IN POUNDS PER CUBIC YARD OF COMMON MINERAL AGGREGATES WITH VARIOUS PERCENTAGES OF VOIDS (SPECIFIC GRAVITY OF 1 = APPROX. 1685 LBS.)

Percentage of Voids

Specific Gravity

25%

30%

35%

40%

45%

50%

Trap Rock

2.8 2.9 3.0 3.1

3540 3660 3790 3910

3300 3420 3540 3650

3070 3180 3290 3390

2830 2930 3030 3130

2600 2690 2780 2870

2360 2440 2530 2610

Granite and Limestone

2.6 2.7 2.8

3280 3410 3540

3060 2850 3180 2960 3300 3070

2630 2410 2730 2500 2830 2600

2190 2270 2360

2.4 2.5 2.6 2.7

3030 3160 3280 3410

2830 2950 3060 3180

2630 2740 2850 2960

2420 2520 2630 2730

2020 2310 2410 2500

2020 2100 2190 2270

2.0 2.1 2.2 2.3 2.4 2.5

2530 2650 2780 2900 3030 3160

2360 2470 2590 2710 2830 2950

2190 2300 2410 2520 2630 2740

2020 2120 2220 2320 2420 2520

1850 1950 2040 2120 2220 2310

1680 1770 1850 1940 2020 2100

Granulated Slag

1.5

1890

1770 1640

1510 1390

1260

Gravel Sand

2.65

3350

3120 2900

2680 2450

2230

Material

Sandstone

Slag

NOTE:

Most limestone, gravel and sand will absorb one percent or more water by weight. Free water in moist sand approximates two percent, moderately wet 4 percent, and very wet seven percent.

DUMPING ANGLES Angles at which different materials will slide on steel Ashes, Dry ..................... 33° Ashes, Moist .................. 38° Ashes, Wet ..................... 30° Asphalt ........................... 45° Cinders, Dry ................... 33° Cinders, Moist ................ 34° Cinders, Wet .................. 31° Cinders & Clay ............... 30° Clay ................................ 45°

Coal, Hard ...................... 24° Coal, Soft ....................... 30° Coke ............................... 23° Concrete......................... 30° Earth, Loose ................... 28° Earth, Compact .............. 50° Garbage ......................... 30° Gravel............................. 40° Ore, Dry ......................... 30°

Ore, Fresh Mined............ 37° Rubble ........................... 45° Sand, Dry ....................... 33° Sand, Moist .................... 40° Sand & Crushed Stone... 27° Stone ............................. 30° Stone, Broken ................ 27° Stone, Crushed .............. 30°

225

DECIMAL EQUIVALENTS OF FRACTIONS Inch

mm

1 64 ⁄ 1 ⁄ 32 3 64 ⁄ 1 ⁄ 16

.39687 .79375 1.1906 1.5875

.015625 .03125 .046875 .0625

33

⁄ 64 17 ⁄ 32 35 ⁄ 64 9 16 ⁄

13.097 13.494 13.891 14.287

.515625 .53125 .546875 .5625

5 64 ⁄ 3 32 ⁄ 7 64 ⁄ 1 8 ⁄

1.9844 2.3812 2.7781 3.1750

.078125 .09375 .109375 .125

37

⁄ 64 19 ⁄ 32 39 ⁄ 64 5 8 ⁄

14.684 15.081 15.478 15.875

.578125 .59375 .609375 .625

⁄ 64 5 32 ⁄ 11 ⁄ 64 3 16 ⁄

9

3.5719 3.9687 4.3656 4.7625

.140625 .15625 .171875 .1875

41

⁄ 64 21 ⁄ 32 43 ⁄ 64 11 ⁄ 16

16.272 16.669 17.066 17.462

.640625 .65625 .671875 .6875

13

⁄ 64 7 32 ⁄ 15 ⁄ 64 1 4 ⁄

5.1594 5.5562 5.931 6.3500

.203125 .21875 .234375 .25

45

⁄ 64 23 ⁄ 32 47 ⁄ 64 3 4 ⁄

17.859 18.256 18.653 19.050

.703125 .71875 .734375 .75

17

⁄ 64 9 32 ⁄ 19 ⁄ 64 5 ⁄ 16

6.7469 7.1437 7.5406 7.9375

.265625 .28125 .296875 .3125

49

⁄ 64 25 ⁄ 32 51 ⁄ 64 13 ⁄ 16

19.447 19.844 20.241 20.637

.765625 .78125 .796875 .8125

21

8.3344 8.7312 9.1281 9.5250

.328125 .34375 .359375 .375

53

⁄ 64 27 ⁄ 32 55 ⁄ 64 7 8 ⁄

21.034 21.431 21.828 22.225

.828125 .84375 .859375 .875

25

⁄ 64 13 ⁄ 32 27 ⁄ 64 7 16 ⁄

9.9219 10.319 10.716 11.112

.390626 .40625 .421875 .4375

57

⁄ 64 29 ⁄ 32 59 ⁄ 64 15 ⁄ 16

22.622 23.019 23.416 23.812

.890625 .90625 .921875 .9375

29

11.509 11.906 12.303 12.700

.453125 .46875 .484375 .5

61

24.209 24.606 25.003

.953125 .96875 .984375

⁄ 64 11 ⁄ 32 23 ⁄ 64 3 8 ⁄

⁄ 64 15 ⁄ 32 31 ⁄ 64 1 2 ⁄ 226

Inch

⁄ 64 31 ⁄ 32 63 ⁄ 64

mm

AREA AND CIRCUMFERENCE OF CIRCLES (INCHES) Dia.

Area

Cir.

Dia.

Area

Cir.

Dia.

Area

Cir.

Dia.

Area

1

⁄ 8

0.0123

.3926

10

78.54

31.41

1

⁄ 4

0.0491

.7854

101 ⁄ 2

86.59

3

⁄ 8

0.1104

1.178

11

1

⁄ 2

0.1963

1.570

5

⁄ 8

0.3067

3

⁄ 4

Cir.

30

706.86

94.24

65

3318.3

204.2

32.98

31

754.76

97.38

66

3421.2

207.3

95.03

34.55

32

804.24 100.5

67

3525.6

210.4

111 ⁄ 2

103.86

36.12

33

855.30 103.6

68

3631.6

213.6

1.963

12

113.09

37.69

34

907.92 106.8

69

3739.2

216.7

0.4417

2.356

121 ⁄ 2

122.71

39.27

35

962.11 109.9

70

3848.4

219.9

7

⁄ 8

0.6013

2.748

13

132.73

40.84

36

1017.8

113.0

71

3959.2

223.0

1

0.7854

3.141

131 ⁄ 2

143.13

42.41

37

1075.2

116.2

72

4071.5

226.1

11 ⁄ 8

0.9940

3.534

14

153.93

43.98

38

1134.1

119.3

73

4185.3

229.3

11 ⁄ 4

1.227

3.927

141 ⁄ 2

165.13

45.55

39

1194.5

122.5

74

4300.8

232.4

13 ⁄ 8

1.484

4.319

14

176.71

47.12

40

1256.6

125.6

75

4417.8

235.6

11 ⁄ 2

1.767

4.712

151 ⁄ 2

188.69

48.69

41

1320.2

128.8

76

4536.4

238.7

15 ⁄ 8

2.073

5.105

16

201.06

50.26

42

1385.4

131.9

77

4656.0

241.9

13 ⁄ 4

2.405

5.497

161 ⁄ 2

213.82

51.83

43

1452.2

135.0

78

4778.3

245.0

17 ⁄ 8

2.761

5.890

17

226.98

53.40

44

1520.5

138.2

79

4901.6

248.1

2

3.141

6.283

171 ⁄ 2

240.52

54.97

45

1590.4

141.3

80

5026.5

251.3

21 ⁄ 4

3.976

7.068

18

254.46

56.46

46

1661.9

144.5

81

5153.0

254.4

21 ⁄ 2

4.908

7.854

181 ⁄ 2

268.80

58.11

47

1734.9

147.6

82

5281.0

257.6

23 ⁄ 4

5.939

8.639

19

283.52

59.69

48

1809.5

150.7

83

5410.6

260.7

3

7.068

9.424

191 ⁄ 2

298.64

61.26

49

1885.7

153.9

84

5541.7

263.8

20

314.16

62.83

50

1963.5

157.0

85

5674.5

257.0

31 ⁄ 4

8.295 10.21

31 ⁄ 2

9.621

10.99

201 ⁄ 2

330.06

64.40

51

2042.8

160.2

86

5808.8

270.1

33 ⁄ 4

11.044

11.78

21

346.36

65.97

52

2123.7

163.3

87

5944.6

272.3

4

12.566

12.56

211 ⁄ 2

363.05

67.54

53

2206.1

166.5

88

6082.1

276.4

41 ⁄ 2

15.904

14.13

22

380.13

69.11

54

2290.2

169.6

89

6221.1

279.6

5

19.635

15.70

221 ⁄ 2

397.60

70.68

55

2375.8

172.7

90

6361.7

282.7

51 ⁄ 2

23.758

17.27

23

415.47

72.25

56

2463.0

175.9

91

6503.8

285.8

6

28.274

18.84

231 ⁄ 2

433.73

73.82

57

2551.7

179.0

92

6647.6

289.0

61 ⁄ 2

33.183

20.42

24

452.39

75.39

58

2642.0

182.2

93

6792.9

292.1

7

38.484

21.99

241 ⁄ 2

471.43

76.96

59

2733.9

185.3

94

6939.7

295.3

71 ⁄ 2

44.178

23.56

25

490.87

78.54

60

2827.4

188.4

95

7088.2

298.4

8

50.265

25.13

26

530.93

81.68

61

2922.4

191.6

96

7238.2

301.5

81 ⁄ 2

56.745

26.70

27

572.55

84.82

62

3019.0

194.7

97

7389.8

304.7

9

63.617

28.27

28

615.75

87.96

63

3117.2

197.9

98

7542.9

307.8

91 ⁄ 2

70.882

29.84

29

660.52

91.10

64

3216.9

201.0

99

7697.7

311.0

227

TRIGONOMETRIC FUNCTIONS

228

Angle

Sin

Cos

Tan

Angle

Sin

Cos

Tan

0 1 2 3 4

0.000 0.017 0.035 0.052 0.070

1.000 0.999 0.999 0.999 0.998

0.000 0.017 0.035 0.052 0.070

46 47 48 49 50

0.719 0.731 0.743 0.755 0.766

0.695 0.682 0.699 0.656 0.643

1.04 1.07 1.11 1.15 1.19

5 6 7 8 9 10

0.087 0.105 0.112 0.139 0.156 0.174

0.996 0.995 0.993 0.990 0.988 0.985

0.087 0.105 0.123 0.141 0.158 0.176

51 52 53 54 55 56

0.777 0.788 0.799 0.809 0.819 0.829

0.629 0.616 0.602 0.588 0.574 0.559

1.23 1.28 1.33 1.38 1.43 1.48

11 12 13 14 15

0.191 0.208 0.225 0.242 0.259

0.982 0.978 0.974 0.970 0.966

0.194 0.213 0.231 0.249 0.268

57 58 59 60 61

0.839 0.848 0.857 0.866 0.875

0.545 0.530 0.515 0.500 0.485

1.54 1.60 1.66 1.73 1.80

16 17 18 19 20

0.276 0.292 0.309 0.326 0.342

0.961 0.956 0.951 0.946 0.940

0.287 0.306 0.325 0.344 0.364

62 63 64 65 66

0.883 0.891 0.898 0.906 0.914

0.469 0.454 0.438 0.423 0.407

1.88 1.96 2.05 2.14 2.25

21 22 23 24 25

0.358 0.375 0.391 0.407 0.423

0.934 0.927 0.921 0.914 0.906

0.384 0.404 0.424 0.445 0.466

67 68 69 70 71

0.921 0.927 0.934 0.940 0.946

0.391 0.375 0.358 0.342 0.326

2.36 2.48 2.61 2.75 2.90

26 27 28 29 30

0.438 0.454 0.469 0.485 0.500

0.898 0.891 0.883 0.875 0.866

0.488 0.510 0.532 0.554 0.577

72 73 74 75 76

0.951 0.956 0.961 0.966 0.970

0.309 0.292 0.276 0.259 0.242

3.08 3.27 3.49 3.73 4.01

31 32 33 34 35

0.515 0.530 0.545 0.559 0.574

0.857 0.848 0.839 0.829 0.819

0.601 0.625 0.649 0.675 0.700

77 78 79 80 81

0.974 0.978 0.982 0.985 0.988

0.225 0.208 0.191 0.174 0.156

4.33 4.70 5.14 5.67 6.31

36 37 38 39 40

0.588 0.602 0.616 0.629 0.643

0.809 0.799 0.788 0.777 0.766

0.727 0.754 0.781 0.810 0.839

82 83 84 85 86

0.990 0.993 0.995 0.996 0.998

0.139 0.122 0.105 0.087 0.070

7.12 8.14 9.51 11.43 14.30

41 42 43 44 45

0.656 0.669 0.682 0.695 0.707

0.755 0.743 0.731 0.719 0.707

0.869 0.900 0.933 0.966 1.000

87 88 89 90

0.999 0.999 0.999 1.000

0.035 0.035 0.017 0.000

19.08 28.64 57.28 Infinity

THEORETICAL WEIGHTS OF STEEL PLATES Size (Inches) 3 16 ⁄ 1 4 ⁄ 5 ⁄ 16 3 8 ⁄ 7 16 ⁄ 1 2 ⁄

Wt. per Sq. Ft. (Lbs.)

7.65 10.20 12.75 15.30 17.85 20.40

Size (Inches)


Size (Inches)


9/16 5/8 3/4 7/8 1 11/8

22.95 25.50 30.60 35.70 40.80 45.90

1 1 ⁄ 4 13 ⁄ 8 1 1 ⁄ 2 5 1 ⁄ 8 3 1 ⁄ 4 2

51.00 56.10 61.20 66.30 71.40 81.60

STANDARD STEEL SHEET GAUGES & WEIGHTS Wt. per Sq. Ft. (Lbs.)


Size (Inches)


Size (Inches)

1 2 3 4 5

.2391 .2242 .2092

11.25 10.625 10.000 9.375 8.750

16 17 18 19 20

.0598 .0538 .0478 .0418 .0359

2.500 2.250 2.000 1.750 1.500

6 7 8 9 10

.1943 .1793 .1644 .1494 .1345

8.125 7.500 6.875 6.250 5.625

21 22 23 24 25

.0329 .0299 .0269 .0239 .0209

1.375 1.250 1.125 1.000 .875

11 12 13 14 15

.1196 .1046 .0897 .0747 .0673

5.000 4.375 3.750 3.125 2.812

26 27 28 29 30

.0179 .0164 .0149 .0135 .0120

Size (Inches)

.750 .6875 .625 .5625 .500

NOTE: (1/4” Thick and Heavier Are Called Plates.) To avoid errors, specify decimal part of one inch or mention gauge number and the name of the gauge. Orders for a definite gauge weight or gauge thickness will be subject to standard gauge weight or gauge thickness tolerance, applying equally plus and minus form the ordered gauge weight or gauge thickness. U.S. Standard Gauge—Iron and steel sheets. Note: U.S. Standard Gauge was established by act of Congress in 1893, in which weights per square foot were indicated by gauge number. The weight, not thickness, is determining factor when the material is ordered to this gauge.

229

APPROXIMATE WEIGHTS PER LINEAL FOOT IN POUNDS OF STANDARD STEEL BARS Dia. In. 1 ⁄ 16 3 ⁄ 32 1 ⁄ 8 5 ⁄ 32 3 ⁄ 16 7 ⁄ 32 1 ⁄ 4 9 ⁄ 32 5 ⁄ 16 11 ⁄ 32 3 ⁄ 8 13 ⁄ 32 7 ⁄ 16 15 ⁄ 32 1 ⁄ 2 17 ⁄ 32 9 ⁄ 16 19 ⁄ 32 5 ⁄ 8 21 ⁄ 32 11 ⁄ 16 23 ⁄ 32 3 ⁄ 4 25 ⁄ 32 13 ⁄ 16

Rd.

.101 .023 .042 .065 .094 .128 .167 .211 .261 .316 .376 .441 .511 .587 .667 .754 .845 .941 1.04 1.15 1.26 1.38 1.50 1.63 1.76

Hex.

.012 .026 .046 .072 .104 .141 .184 .233 .288 .348 .414 .486 .564 .647 .736 .831 .932 1.03 1.15 1.27 1.39 1.52 1.66 1.80 1.94

Sq.

.013 .030 .053 .083 .120 .163 .212 .269 .332 .402 .478 .561 .651 .747 .850 .960 1.08 1.20 1.33 1.46 1.61 1.76 1.91 2.08 2.24

Dia. In.

⁄ 32 7 ⁄ 8 29 ⁄ 32 27

⁄ 16

15

⁄ 32

31

1 1 1 ⁄ 16 1 1 ⁄ 8 3 1 ⁄ 16 1 1 ⁄ 4 5 1 ⁄ 16 3 1 ⁄ 8 7 1 ⁄ 16 1 1 ⁄ 2 5 1 ⁄ 8 3 1 ⁄ 4 7 1 ⁄ 8 2 1 2 ⁄ 8 1 2 ⁄ 4 3 2 ⁄ 8 1 2 ⁄ 2 3 2 ⁄ 4 3

Rd.

.190 2.04 2.19 2.35 2.51 2.67 3.01 3.38 3.77 4.17 4.60 5.05 5.52 6.01 7.05 8.18 9.39 10.68 12.06 13.52 15.06 16.69 20.20 24.03

Hex.

2.10 2.25 2.42 2.59 2.7 2.95 3.32 3.37 4.15 4.60 5.07 5.57 6.09 6.63 7.78 9.02 10.36 11.78 13.30 14.91 16.61 18.40 22.27 26.50

Sq.

2.42 2.60 2.79 2.99 3.19 3.40 3.84 4.30 4.80 5.31 5.86 6.43 7.03 7.65 8.98 10.41 11.95 13.60 15.35 17.21 19.18 21.25 25.71 30.60

WEIGHTS OF FLAT BARS AND PLATES To find weight per foot of flat steel, multiply width in inches by figure listed below: Thickness 1 ⁄ 16” ........................ .2125 1 1 ⁄ 8” ....................... .4250 3 ⁄ 16” ........................ .6375 1 ⁄ 4” ......................... .8500 5 ⁄ 16” ...................... 1.0600 3 ⁄ 8” ....................... 1.2750 7 ⁄ 16” ...................... 1.4880 1 ⁄ 2” ....................... 1.7000 9 ⁄ 16” ...................... 1.9130 5 ⁄ 8” ....................... 2.1250 11 ⁄ 16” ..................... 2.3380 3 ⁄ 4” ....................... 2.5500 13 ⁄ 16” ............................................2.7630 ...............................1 11 ⁄ 16”

Thickness 7 ⁄ 8” ......................... 2.975 15 ⁄ 16” ....................... 3.188 1” .......................... 3.400 11 ⁄ 16” ....................... 3.613 1 1 ⁄ 8” ....................... 3.825 13 ⁄ 16” ....................... 4.038 1 1 ⁄ 4” ....................... 4.250 15 1 ⁄ 16” ..................... 4.463 3 1 ⁄ 8” ....................... 4.675 7 1 ⁄ 16” ...................... 4.888 1 1 ⁄ 2” ....................... 5.100 9 1 ⁄ 16” ...................... 5.313 5 1 ⁄ 8” ....................... 5.525 5.738

Thickness 3 1 ⁄ 4” .......................5.950 113 ⁄ 16”.....................6.163 7 1 ⁄ 8” .......................6.375 15 1 ⁄ 16”.....................6.588 2” .........................6.800 1 2 ⁄ 8” .......................7.225 1 2 ⁄ 4” .......................7.650 3 2 ⁄ 8” .......................8.075 1 2 ⁄ 2” .......................8.500 5 2 ⁄ 8” .......................8.925 3 2 ⁄ 4” .......................9.350 7 2 ⁄ 8” .......................9.775 3” .......................10.200

APPROXIMATE WEIGHT OF VARIOUS METALS To find weight of various metals, multiply contents in cubic inches by the number shown; result will be approximate weight in pounds. Iron . . . . . . . .27777 Brass. . . . . . .31120 Tin. . . . . . . . .26562 Steel . . . . . . .28332 Lead . . . . . . .41015 Aluminum . . .09375 Copper . . . . .32118 Zinc . . . . . . . .25318

230

STEEL WIRE GAUGE DATA

Ga. No.

Birmingham Wire Gauge or Stubs Gauge Thickness *Wt. per Inches Sq. Ft.

Brown & Sharpe or American Wire

Steel Wire Gauge (Washburn & Moren)

3 4 5

.259 .238 .220

10.567 9.710 8.976

.2294 .2043 .1819

.2437 .2253 .2070

6 7 8 9 10

.203 .180 .165 .148 .134

8.282 7.344 6.732 6.038 5.467

.1620 .1443 .1285 .1144 .1019

.1920 .1770 .1620 .1483 .1350

11 12 13 14 15

.120 .109 .095 .083 .072

4.896 4.447 3.876 3.386 2.938

.0907 .0808 .0720 .0641 .0571

.1205 .1055 .0915 .0800 .0720

16 17 18 19 20

.065 .058 .049 .042 .035

2.652 2.366 1.999 1.714 1.428

.0508 .0453 .0403 .0359 .0320

.0625 .0540 .0475 .0410 .0348

21 22 23 24 25

.032 .028 .025 .022 .020

1.306 1.142 1.020 .898 .816

.0285 .0253 .0226 .0201 .0179

.0317 .0286 .0258 .0230 .0204

26 27 28 29 30

.018 .016 .014 .013 .012

.734 .653 .571 .530 .490

.0159 .0142 .0126 .0113 .0100

.0181 .0173 .0162 .0150 .0140

NOTE: Birmingham or Stubs Gauge—Cold rolled strip, round edge flat wire, cold roll spring steel, seamless steel and stainless tubing and boiler tubes. *B.W. Gauge weights per sq. ft. are theoretical and based on steel weight of 40.8 lbs. per sq. ft. of 1” thickness; weight of hot rolled strip is predicted by using this factor. Steel Wire Gauge—(Washburn & Moen Gauge)—Round steel wire in black annealed, bright basic, galvanized, tinned and copper coated.

231

ROCKWELL-BRINELL CONVERSION TABLE Brinell Numbers 10 mm Ball 3000 kg Load

Rockwell C Scale Brale Penetrator 150 kg Load

Brinell Numbers 10 mm Ball 3000 kg Load

Rockwell C Scale Brale Penetrator 150 kg Load

690 673 658 645 628 614 600 587 573 560

65 64 63 62 61 60 59 58 57 56

393 382 372 362 352 342 333

42 41 40 39 38 37 36

547 534 522 509 496 484 472 460 448 437

55 54 53 52 51 50 49 48 47 46

322 313 305 296 290 283 276 272 265 260

35 34 33 32 31 30 29 28 27 26

426 415 404

45 44 43

255 248 245 240 235 230

25 24 23 22 21 20

AMERICAN STANDARD COARSE AND FINE THREAD SERIES

Size 0 1 2 3 4 5 6 8 10 12 1 ⁄ 4 5 ⁄ 16 3 8 ⁄ 7 ⁄ 16 1 2 ⁄

232

Threads per inch Coarse Fine NC NF 64 56 48 40 40 32 32

80 72 64 56 48 44 40 36

24 24 20 18 16 14 13

32 28 28 24 24 20 20

Size 9 ⁄ 16 5 ⁄ 8 3 4 ⁄ 7 ⁄ 8

1 1 1 ⁄ 8 1 1 ⁄ 4 3 1 ⁄ 8 1 1 ⁄ 2 3 1 ⁄ 4 2 1 2 ⁄ 4 1 2 ⁄ 2 3 2 ⁄ 4 3 Over 3

Threads per inch Coarse Fine NC NF 12 11 10 9 8 7 7 6

18 18 16 14 14 12

6 5 1 4 ⁄ 2 1 4 ⁄ 2 4 4 4

12

SPEED RATIOS Speed ratios and groups from which speed change selection can be made. Revolutions per minute of faster shaft Ratio of transmission = Revolutions per minute of slower shaft Number of Teeth in Driver Gear & Sprocket

t e k c o r p S & r a e G n e v i r D n i h t e e T f o r e b m u N

19 21 23 25 27 30 33 36 40 45 50 55 60 68 75 84 90 102

19 21 23 25 27 30 33 36 40 45 50 55

17 19 21 23 25 27 30 1.12 1.00 0.91 0.83 0.76 0.70 0.64 1.23 1.10 1.00 0.91 0.84 0.78 0.70 1.35 1.21 1.10 1.00 0.92 0.85 0.78 1.47 1.32 1.19 1.09 1.00 0.93 0.83 1.59 1.42 1.28 1.17 1.08 1.00 0.90 1.77 1.58 1.43 1.30 1.20 1.11 1.00 1.94 1.74 1.57 1.43 1.32 1.22 1.19 2.12 1.89 1.71 1.56 1.44 1.33 1.20 2.35 2.10 1.90 1.74 1.60 1.48 1.33 2.65 2.37 2.14 1.96 1.80 1.67 1.50 2.94 2.63 2.38 2.18 2.00 1.85 1.67 3.24 2.89 2.62 2.39 2.20 2.04 1.83 3.53 3.16 2.86 2.61 2.40 2.22 2.00 4.00 3.58 3.24 2.96 2.72 2.52 2.27 4.41 3.95 3.57 3.26 3.00 2.78 4.94 4.42 4.00 3.65 3.36 5.30 4.74 4.28 3.91 6.00 5.37 4.86 Number of Teeth in Driver Gear & Sprocket 36 40 45 50 55 60 68 0.53 0.48 0.42 0.38 0.35 0.32 0.28 0.58 0.53 0.47 0.42 0.38 0.35 0.31 0.64 0.58 0.51 0.46 0.42 0.38 0.34 0.70 0.63 0.56 0.50 0.46 0.42 0.37 0.75 0.68 0.60 0.54 0.49 0.45 0.40 0.83 0.75 0.67 0.60 0.55 0.50 0.44 0.92 0.83 0.73 0.66 0.60 0.55 1.00 0.90 0.80 0.72 0.65 1.11 1.00 0.89 0.80 1.25 1.13 1.00 1.30 1.25 1.53

33 0.58 0.65 0.70 0.76 0.82 0.91 1.00 1.09 1.21 1.36 1.52 1.67 1.82

75 0.25 0.28 0.31 0.33 0.36

GENERAL INFORMATION ON CHAINS The chain drive has three elements; the driver sprocket, the driven sprocket, and the endless chain which transmits power form the first to the second. The distance from center to center of adjacent chain pins is the chain pitch and also the sprocket pitch. Chain speed, f.p.m. = H.P. of drive

=

No. of teeth in sprocket x chain pitch (in.) x r.p.m. 12 Chain speed in f.p.m. x pull in pounds 33,000

Chain speed, except for high speed RC and silent chains, should 1 the not exceed 500 ft. per min. Working load should be held under ⁄ 6 ultimate strength for speeds up to 200 f.p.m., 1/10 where speed is between 200 and 300 f.p.m., and less if speed exceeds 300 f.p.m.

233

CONVERSION OF THERMOMETER SCALE Centigrade — Fahrenheit °C. = 5/9 (°F.—32) °F. = 9/5 °C. + 32

°C. °F. -80 -112. -70 -94. -60 -76. -50 -58.0 -45 -49.1 -40 -40.0 -35 -31.0 -30 -22.0 -25 -13.0 -20 -4.0 -19 -2.2 -18 -.4 -17 1.4 -16 3.2 -15 5.0 -14 6.8 -13 8.6 -12 10.4 -11 12.2 -10 14.0 -9 15.8 -8 17.6 -7 19.4 -6 21.2 -5 23.0 -4 24.8 -3 26.6 -2 28.4 -1 30.2 0 32.0

°C. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

°F. 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0

°C. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

°F. 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 114.8 116.0 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0

°C. 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

°F. 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0

°C. 91 92 93 94 95 96 97 98 99 100 105 110 115 120 130 140 150 160 170 180 190 200 250 300 350 400 500 600 700 800 900 1000

°F. 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221. 230. 239. 248. 266. 284. 302. 320. 338. 356. 374. 392. 482. 572. 662. 752. 932. 1112. 1292. 1472. 1652. 1832.

MISCELLANEOUS USEFUL INFORMATION To find capacity in U.S. gallons of rectangular tanks, multiply length by width by depth (all in inches) and divide result by 231. To find number of U.S. gallons in pipe or cylinder, divide cubic contents in inches by 231. Doubling the diameter of a pipe increases its capacity four times. To find pressure in pounds per square inch of column of water, multiply height of column in feet by .434; to find height of column of water when pressure in pounds per square inch is known, multiply pressure in pounds by 2.309 (2.309 Feet Water exerts pressure on one pound per square inch.)

234

APPROX. SAFE LOAD FOR CHAINS AND WIRE ROPES UNDER DIFFERENT LOADING CONDITIONS Alloy Sling Chain ASTM A-391 Approx. Working Load Limits

Single Leg

Alloy Chain Size Inch mm Lbs. kg 1 6.35 3,250 1474 ⁄ 4 3 ⁄ 8

9.52 6,600

Double Leg

Lbs. kg Lbs. kg 5,660 2563 4,600 2086

Lbs. kg 3,250 1474

2994 11,400 5171 9,300 4218

6,600 2994

1 ⁄ 2

12.7

11,250 5103 19,500 8845 15,900 7212 11,250 5103

5 ⁄ 8

15.9

16,500 7484 28,600 12973 23,300 10559 16,500 7484

3 ⁄ 4

19.0

23,000 10433 39,800 18053 32,500 14742 23,000 10433

7 ⁄ 8

22.2

28,750 13041 49,800 22589 40,700 18461 28,750 13041

1

25.4

38,750 17577 67,100 30436 54,800 24857 38,750 17577

1 1 ⁄ 4

31.7

57,500 26082 99,600 45178 81,300 36878 57,500 26082

The above Working Load Limits are based upon using chain having a working load equal to that shown in column for single leg. - Courtesy of The Crosby Group

WIRE ROPE

RATED CAPACITY (Approx.) Single-Part Rope Body Size

1 Sling Vertical 2 Legs

60° 2 Legs

45°

2 Legs

30°

mt Tons* 1.6 3.2

mt 2.9

Tons* 2.6

mt 2.4

Tons* 1.8

mt 1.6

Inch 1 2 ⁄

mm 12.7

Tons* 1.8

9 ⁄ 16

14.3

2.3

2.1

4.0

3.6

3.2

2.9

2.3

2.1

5 ⁄ 8

15.9

2.8

2.5

4.8

4.4

4.0

3.6

2.8

2.5

3 4 ⁄

19.0

3.9

3.5

6.8

6.2

5.5

5.0

3.9

3.5

7 ⁄ 8

22.2

5.1

4.6

8.9

8.1

7.3

6.6

5.1

4.6

1

25.4

6.7

6.1

11.0

10.0

9.4

8.5

6.7

6.1

1 1 ⁄ 8

28.6

8.4

7.6

14.0

12.7

12.0

10.9

8.4

7.6

1 1 ⁄ 4

31.7

10.0

9.1

18.0

16.3

15.0

13.6

10.0

9.1

3 1 ⁄ 8

34.9

12.0

10.9

21.0

19.0

17.0

15.4

12.0

10.9

1 1 ⁄ 2

38.1

15.0

13.6

25.0

22.7

21.0

19.0

15.0

13.6

5 1 ⁄ 8

41.3

17.0

15.4

30.0

27.2

24.0

21.8

17.0

15.4

3 1 ⁄ 4

44.4

20.0

18.1

34.0

30.8

28.0

25.4

20.0

18.1

7 1 ⁄ 8

47.6

22.0

20.0

39.0

35.4

34.0

30.8

22.0

20.0

2

50.8

26.0

23.6

44.0

40.0

36.0

32.6

26.0

23.6

*Ton = 2,000 lbs.

- Courtesy Macwhyte Company

235

AVERAGE SAFE CONCENTRATED LOADS ON WOODEN BEAMS—AVERAGE CONDITIONS

Beam Dimension

Span

Width

Load

Depth

Ft.

meters

In.

mm

In.

mm

4

1.219

6

152

6

152

2,100 952.6

8

203

8

203

4,970 2254

8

203

10

254

7,765 3522

6

152

6

6

152

8

8

203

8

8

203

10

10

254

10

10

254

12

12

305

12

6

152

6

6

152

8

8

203

8

8

203

10

6

8

1.829

2.438

Lbs.

kg

3 ⁄ 1 d e s a 203 2,490 1129 e r c n 203 3,320 1506 i e b 254 5,184 2351 n a c 254 6,480 2939 d a o l e 305 9,330 4232 h t s n 305 11,197 5097 o i t i d n o c 152 1,050 476.3 l a e d i 203 1,866 846.4 r e d n 203 2,488 1128 U

152

1,398 634.1

10

254

3,888 1763

254

10

254

4,860 2204

10

254

12

305

7,000 3175

12

305

12

305

8,400 3810

1 2 of uniformly distributed load. Concentrated Load = ⁄

236

4 7 0 6 2 5 8 3 9 6 2 8 4 9 9 3 0 0 6 3 5 8 4 0 3 5 8 1 3 6 8 1 6 1 1 3 4 6 9 2 4 6 9 2 5 9 2 5 8 5 1 1 1 1 2 2 2 2 3 3 3 4 4 4 6

T A D A O R F O E L I ) e M t E o N N O e R e ) s O e S F ( h c n I D — ( E S H R T I H T E U P P D Q E E D E R E S O O E L S T A O O G E L R D G N G A A F S O H T S D D I W R S A Y U O C I I B R A U C V E T A M I X O R P P A s .

0 7 0 4 0 7 1 3 8 1 5 8 0 7 7 3 7 2 6 6 5 0 4 4 3 2 2 1 0 4 6 9 4 7 0 5 8 1 1 1 3 1 4 1 1 2 2 2 3 2 6 2 9 2 2 3 3 3 1 4 4 4 8 5 3 3 4 5 2 5 5 6 7 0 7 8 8 8 4 1 5 0 4 7 0 6 5 8 4 6 2 8 8 1 1 8 3 5 8 1 0 1 1 1 3 1 1 1 9 1 0 2 3 2 6 2 8 2 1 3 3 3 6 3 9 3 2 5 7 1 9 7 1 7 3 1 0 8 6 4 2 3 3 2 4 6 9 1 2 5 8 1 3 6 9 2 6 7 4 1 1 0 1 3 5 7 8 0 2 5 7 9 1 4 5 1 9 1 1 1 1 1 1 2 2 2 2 2 3 3 4 3 9 7 4 0 6 2 7 3 8 3 1 2 0 8 7 6 6 6 6 5 5 4 4 3 3 1 6 8 8 8 7 9 7 8 9 1 3 4 5 7 9 1 3 5 7 9 1 1 1 1 1 1 2 2 2 2 2 9 3

1 2 4 7 0 3 6 9 2 4 9 2 3 5 8 4 2 0 6 3 9 5 1 8 4 5 5 1 5 3 1 7 8 6 7 8 9 1 2 3 4 6 7 9 1 2 4 2 1 1 1 1 1 1 1 2 2 2 3 2 3 4 4 4 4 4 6 7 7 2 2 2 7 5 1 4 7 0 3 6 9 2 5 0 4 6 2 8 5 8 1 7 5 6 5 5 6 7 9 9 0 1 1 1 3 1 4 1 1 1 8 1 9 1 6 2

6 3 1 9 7 6 1 0 9 7 8 5 3 2 0 8 7 7 7 6 6 5 3 9 9 4 8 8 3 8 8 7 4 3 4 4 5 6 7 7 8 9 0 1 2 3 4 9 1 1 1 1 1 1 4 1 3 6 1 6 9 1 7 2 7 2 7 3 9 2 3 6 9 2 9 5 8 2 8 5 1 8 4 1 7 3 2 2 3 3 4 4 5 5 6 7 7 8 9 8 0 3 1 0 7 3 6 8 4 1 3 6 8 1 4 6 9 2 1 6 3 4 6 9 2 4 6 9 2 5 9 2 5 8 5 1 1 1 1 1 2 2 2 2 3 3 3 4 4 4 6

0 3 7 0 3 7 0 7 3 0 7 0 3 0 7 d e r 7 6 3 0 8 5 2 0 6 l 8 6 4 1 0 8 Y e i 8 9 5 1 7 9 0 2 4 6 4 6 2 8 0 2 8 . P 5 2 4 5 6 7 3 M 4 5 5 7 8 8 3 9 0 q 1 1 1 1 1 1 1 2 S f o d ) . 1 8 9 0 2 4 5 6 8 0 2 4 6 8 0 0 h a t t o F 1 1 1 1 1 1 2 2 2 2 2 3 4 d i R ( W

238

o t % 5 1 s e r u g i f e v o b a e h t e s a e r c n i , n o i t c a p m o c r e t f a h t p e d r o f d e r i u q e r l a i r e t a m f o t n u o m a e h t n i a t b o o T . l . a g i r n o t l e a e l m i f m o 1 n o d i t n a a d e d r i a g w d ’ n 1 a , p e e p e t d y e ” 1 h t n — s o d g r a n i y d c n i e b p u e c d 0 3 . % 0 6 3 1 : E T O N

S 7 0 7 . 0 . 3 . 0 3 7 0 3 7 3 3 6 0 3 7 0 3 7 . 3 . 6 . 3 . 3 . 6 H . . . . . . . . . . . . . . . 0 3 3 3 0 3 2 0 3 6 0 3 6 3 3 6 0 3 6 0 3 6 T 3 6 3 3 6 0 3 1 0 3 6 0 3 6 3 3 6 0 3 6 0 3 6 0 0 0 1 1 1 2 2 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 0 P 1 1 1 1 1 1 1 1 E D S U 0 2 . 8 . 6 4 2 0 8 6 4 1 9 7 4 2 0 8 6 3 2 9 4 4 . . . . . . . . . . . . . . . . . . . . . O 0 7 0 I 6 4 2 0 7 5 3 1 8 6 4 2 0 7 5 3 1 8 4 4 2 2 1 1 4 7 0 2 5 8 1 3 6 9 2 5 7 0 3 6 8 4 4 7 0 0 R 4 4 4 5 5 5 5 6 6 6 6 7 7 7 8 8 8 8 9 9 9 0 1 1 A V T A 0 S . 0 . 0 . 0 . 0 . 0 . 5 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 9 E 7 0 5 4 7 0 5 6 7 0 5 8 7 0 I 3 4 2 4 4 5 2 5 5 5 7 5 0 6 2 6 6 7 2 7 5 7 7 7 0 8 2 8 8 9 2 9 T I S N E D 7 7 . 0 . 2 . . 5 . 8 . 0 . 2 . 4 . 6 . 9 . 1 . 3 . 5 . 8 . 0 . 2 . 4 . 6 . 9 . 1 . 3 . 5 . 8 3 5 7 0 2 4 8 1 3 5 7 0 2 4 8 1 3 5 7 0 2 G 8 3 3 5 3 7 0 N 3 3 4 2 4 4 4 6 4 8 4 1 5 3 5 5 5 7 5 0 6 2 6 4 6 6 6 8 6 1 7 3 7 5 7 7 7 0 8 2 8 I Y R A V 7 7 7 . 0 . 4 . . 0 . 4 . 0 . 4 . 9 . 3 . 8 . 2 . 6 . 1 . 6 . 0 . 4 . 9 . 3 . 8 . 2 . 1 . 1 . 6 1 1 0 0 9 8 8 7 7 6 5 5 4 3 3 2 2 1 0 0 7 9 1 3 5 6 8 0 2 4 6 8 0 2 4 6 6 0 2 4 6 8 0 9 F 2 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 7 1 7 O S E ) T s e A h G c 7 0 7 7 7 7 7 7 7 n . 0 . 6 . . 6 . 3 . 0 . 6 . 3 . 0 . 6 . 3 . 0 . 6 . 3 . 0 . 6 . 3 . 0 . 6 . 3 . 0 . 6 . 3 E I 0 3 0 3 0 3 0 3 0 3 0 3 0 3 0 ( 6 5 6 8 0 1 3 5 6 8 0 1 3 5 6 8 0 1 3 5 6 8 0 2 R H 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 G T P G D A E F O 3 7 5 7 5 . 2 . 1 . 0 . 9 . 8 . 1 . 6 . 9 . 3 . 2 . 1 . 0 . 9 . 8 . 6 . 6 . 4 . 3 . 2 . 1 . 0 . 9 . 8 2 6 0 3 7 5 3 7 1 5 8 2 0 8 2 6 0 3 5 D 0 5 6 7 9 7 8 5 4 7 8 2 2 2 3 2 2 2 2 2 0 3 1 3 3 3 4 3 6 3 3 3 0 4 1 4 3 4 4 4 4 4 0 5 1 5 R A Y E R A 7 7 7 . 8 . 9 . 0 . 1 . 2 . 3 . 4 . 5 . 6 . 8 . 9 . 0 . 1 . 2 . 3 . 4 . 5 . 6 . 8 . 9 . 0 . 1 . 7 8 0 1 2 3 4 5 7 8 0 1 2 3 4 5 7 8 0 1 U 4 6 6 7 8 5 6 7 8 5 6 7 8 Q 1 1 1 0 2 1 2 2 2 3 2 4 2 2 2 2 2 0 3 1 3 2 3 3 3 4 3 3 3 3 3 0 4 1 4 S R E P 7 0 7 7 7 7 7 S . 0 . 3 . . 3 . 6 . 0 . 3 . 6 . 0 . 3 . 1 . 0 . 3 . 6 . 0 . 3 . 1 . 0 . 3 . 6 . 0 . 3 . 1 5 3 1 0 8 5 3 0 8 5 3 0 8 5 3 0 8 D 3 2 3 4 5 5 6 7 8 9 0 0 1 2 3 4 5 5 6 7 8 9 0 0 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 N U O P N 0 7 7 3 9 5 . 5 . 1 . 6 . 2 . 8 . 3 . 9 . 4 . 0 . 5 . 1 . 6 . 2 . 8 . 3 . 9 . 4 . 0 . 5 . I . . . 0 5 1 2 7 3 8 4 0 5 1 2 7 3 8 4 0 5 2 3 8 4 0 1 1 2 2 3 3 4 5 1 5 6 6 7 1 7 8 8 9 0 0 T 8 8 9 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 H G I E W E 0 2 . 8 . 7 2 0 8 6 3 1 9 7 4 2 0 8 6 3 1 9 7 4 T . 4 . . . . . . . . . . . . . . . . . . . . 1 1 0 2 4 7 0 2 5 8 1 3 6 9 2 5 7 0 3 6 8 1 4 7 A 4 4 4 5 5 5 5 6 6 6 6 7 7 7 8 8 8 8 9 9 9 0 1 0 1 M I X O y r ) R t e d i 0 0 0 p 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 s Y . 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P n . s 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 e b P u 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 A D L ( C 239

b a , l s a 2 7 2 1 6 1 0 7 6 7 8 5 0 6 1 6 0 9 7 6 4 3 1 9 8 6 5 a e . 1 3 6 7 5 4 2 . . . . . r . 1 . 1 . 1 . 1 . 3 . 5 . 7 . 9 . 1 2 4 6 8 f 6 1 . 3 . 5 . 7 . 9 . 1 1 1 1 1 1 o a S t . t f S n . e q t E s n N 0 o c 0 K 9 8 8 8 8 5 c 2 9 6 3 0 0 0 9 9 i 5 7 4 1 8 5 1 8 5 2 9 1 . 0 1 3 5 7 4 1 7 4 . . . . . C . 1 . 1 . 1 . 1 . 3 . 5 . 6 . 8 . 0 1 3 5 6 b d 5 1 . 3 . 4 . 6 . 8 . 1 I 1 1 1 1 1 u c n H a e T h t s s e d D n n k i N f i c 5 9 3 0 8 4 9 5 9 3 7 2 6 0 5 1 6 2 7 3 8 3 8 4 o . 0 2 3 5 0 6 1 7 2 . . . . h A . 1 . 1 . 1 . 3 . 4 . 6 . 7 . 9 . 0 2 3 5 T t 5 1 . 3 . 4 . 6 . 7 . 9 . 1 1 1 1 1 : ” S s e 6 l A b p a l E m s a R a x f E 1 0 9 A 5 9 8 7 6 0 3 2 . o 5 4 8 2 6 0 3 7 1 1 5 8 . 1 2 3 7 1 5 0 3 7 . . . n t 1 2 4 5 7 8 9 . . . . . . . . . 4 . . . . . . . 1 2 3 S 1 1 1 2 4 5 7 8 9 1 1 1 w n e t o U n h o s O c I e c s i R o b 1 5 h 0 1 4 7 0 4 7 1 4 8 A t u 0 3 5 7 0 2 4 7 1 3 . 0 1 2 4 7 9 1 4 6 8 . . c 1 2 3 5 6 7 8 . . . . . . . . . . 4 . . . . . . . 1 1 1 2 3 4 6 7 8 9 1 2 V ) n e 1 1 a h s e h t F h t d c a O I n n e i ( r f a o S S B d T B A n 0 L 4 2 8 6 4 2 0 8 6 t . a 5 1 2 3 3 4 5 6 7 7 8 f A S . 0 1 2 3 4 4 5 6 7 . . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . 0 s . 3 1 . 2 , 3 . 4 . 5 . 6 . 7 . 8 . 9 . 1 L F 1 s q e s S O n S 0 k S c 0 E i N 0 I N h 1 t K C r r I E H e o 1 3 6 5 8 0 3 6 8 t f 9 9 8 7 6 6 5 4 4 3 T T 0 . 8 7 7 6 5 4 4 3 2 a . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . e ” 3 0 . 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . 1 E 2 r g d R f n o a C s ” N b . a 6 r l s O e s s d f 4 2 0 6 3 0 0 5 2 e C 5 8 6 3 1 9 6 4 2 0 8 . 5 3 1 8 6 4 2 9 7 n o n 0 1 2 3 3 4 5 6 7 7 . . . . . . . . . 2 . . . . . . . . . . 1 2 3 3 4 5 6 6 7 t u k F c n i n e e t O t v h n i ” o g S c s 6 r c e D i e r b d R u 4 6 7 u i 3 5 4 7 9 0 2 0 6 2 9 5 1 7 3 9 6 2 g n . 2 8 0 7 3 9 5 1 u 0 1 1 2 3 3 4 4 5 6 . . . . . . . . . c f A 2 . . . . . . . . . . 1 1 2 3 3 4 4 5 6 . e t e Y f h t h . t q e C t s I a d d 0 a B m i , 0 t 5 s U s 9 3 2 8 4 0 7 3 s 5 5 9 4 9 3 8 2 7 2 6 3 . 3 8 3 7 2 7 1 6 e d e . 1 . 2 . 2 . 3 . 3 . 4 . 4 . C 1 0 . 0 . 1 . 1 . 2 . 2 . 3 . 3 . 4 . 4 . 9 . 1 n n o a t k E c 0 d i e 0 T h t s 0 u ” A 1 8 r e M o b d f I n y X 0 a a n 7 8 9 3 4 5 6 . 3 6 9 2 5 9 2 5 8 1 2 3 e 2 5 8 1 4 7 0 1 0 0 0 1 1 1 2 2 2 3 6 9 . . . . . . . v . . . . . . . . . . . . 1 1 1 2 2 2 3 m a O i e r g e l a R b t . s e a P t f r . u P s i q g i e s h f A a r ) 0 T t a 0 0 0 0 0 0 0 0 0 0 e e 0 0 0 0 0 0 0 0 0 0 e u 0 0 0 0 0 0 0 : 0 0 r 0 1 2 3 4 5 6 7 8 9 0 e h q 1 2 3 4 5 6 7 8 9 E A S F 1 T 0 t ( d O 1 f a N o d 240

DEFINITIONS AND TERMS Admixtures—Substances, not normally a part of paving materials or mixtures, added to them to modify their properties. Agglomeration—Gathering into a ball or mass. Aggregates—In the case of materials for construction, essentially inert materials which when bound together into a conglomerated mass by a matrix form asphalt, concrete, mortar or plaster; crushed rock or gravel screened to size for use on road surfaces. Ballast—Broken stone or gravel used in stabilizing a road bed or making concrete. Bank Gravel—Gravel found in natural deposits, usually more or less intermixed with fine material, such as sand or clay, or combinations thereof; gravelly clay, gravelly sand, clayey gravel, and sandy gravel, indicate the varying proportions of the materials in the mixture. Base—Foundation for pavement. Beneficiation—Improvement of the chemical or physical properties of a material or intermediate product by the removal of undesirable components or impurities. Binder Course—The course, in sheet asphalt and bituminous concrete pavements, placed between base and surface courses. Binder Soil—Material consisting primarily of fine soil particles (fine sand, silt, true clay and colloids); good binding properties; commonly referred to as clay binder. Bleeding—Upward migration of bituminous material, resulting in film of bitumen on surface. Blow-up—Localized buckling or shattering of rigid pavement caused by excessive longitudinal pressure. Bog —Wet spongy ground, sometimes filled with decayed vegetable matter. Boulders—Detrital material greater than about 8” in diameter. Construction Joint—Vertical or notched plane of separation in pavement. Contraction Joint—Joint of either full depth or weakened 241

DEFINITIONS AND TERMS

(Continued)

plane type, designed to establish position of any crack caused by contraction, while providing no space for expansion of pavement beyond original length. Corrugations—Regular transverse undulation in surface of pavement consisting of alternate valleys and crests. Cracks—Approximately vertical cleavage due to natural causes or traffic action. Crazing—Pattern cracking extending only through surface layer, a result of more drying shrinkage in surface than interior of plastic concrete. “D” Lines—Disintegration characterized by successive formation of series of fine cracks at rather close intervals paralleling edges, joints and cracks, and usually curving across slab corners. Initial cracks forming very close to slab edge and additional cracks progressively developing, ordinarily filled with calcareous deposit. Dense and Open Graded Aggregates—Dense applies to graded mineral aggregate containing sufficient dust or mineral filler to reduce all void spaces in compacted aggregate to exceedingly small diameters approximating size of voids in filler itself, may be either coarse or fine graded; open applies to graded mineral aggregate containing no mineral filler or so little that void spaces in compacted aggregate are relatively large. Dewater—To remove water by pumping, drainage, or evaporation, or a dewatering screw. Disintegration—Deterioration into small fragments from any cause. Distortion—Any deviation of pavement surface from original shape. Expansion Joint—Joint permitting pavement to expand in length. Faulting—Differential vertical displacement of slabs adjacent to joint or crack. Flume—An open conduit of wood, concrete or metal. Gradation—Sieve analysis of aggregates, a general term to describe the aggregate composition of a mix. 242


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Gradation Aggregates—Percentages of aggregate in question which fall into specified size limits. Purpose of grading aggregates is to have balanced gradation of aggregate so that voids between sizes are progressively filled with smaller particles until voids are negligible. Resulting mix reaches highest mechanical stability without binder. Granites—Crystalline, even-grained rocks consisting essentially of feldspar and quartz with smaller amounts of mica and other ferro-magnesian minerals. Gravel —Granular, pebbly material (usually coarser than 1/4” in diameter) resulting from natural disintegration of rock; usually found intermixed with fine sands and clay; can be identified as bank, river or pea gravel; rounded character of some imparted by stream action. Gravity—The force that tends to pull bodies towards the center of mass, to give bodies weight. Grit—A coarse sand formed mostly of angular quartz grains. Gumbo—Soil of finely divided clays of varying capillarity. “Hollows”—Deficiencies in certain fractions of a pitrun gravel. Igneous—Natural rock composed of solidified molten material. Lime Rock—Natural material essentially calcium carbonate with varying percentages of silica; hardens upon exposure to elements; some varieties provide excellent road material. Limestone—Natural rock of sedimentary origin composed principally of calcium carbonate or calcium and magnesium carbonates in either its original chemical or fragmental, or recrystallized form. Loam—Soil which breaks up easily, usually consisting of sand, clay and organic material. Loess—An unstratified deposit of yellow-brown loam. 3 8” mateManufactured Sand—Not natural occurring sand, - ⁄ 3 8” material. rial made by crushing + ⁄

Mesh—The number of openings per lineal inch in wire screen. Metamorphic Rock—Pre-existing rock altered to such an extent as to be classed separately. One of the three basic rock formations, including igneous and sedimentary. 243


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Micron—A unit of length; one thousandth of a millimeter. Mineral Dust or Filler—Very finely divided mineral product, great bulk of which will pass No. 200 sieve. Pulverized limestone is most commonly manufactured filler; other stone dust, silica, hydrated lime and certain natural deposits of finely divided mineral matter are also used. Muck—Moist or wet decaying vegetable matter or peat. Natural Cement—Product obtained by finely pulverizing calcined argillaceous limestone, to which not to exceed 5 percent of nondeleterious materials may be added subsequent to calcination. Temperature of calcination shall be no higher than necessary to drive off carbonic acid gas. Ore—Any material containing valuable metallic matter which is mined or worked. Outcropping —A stratum of rock or other material which breaks surface of ground. Overburden—Soil mantle, waste, or similar matter found directly above deposit of rock or sand-gravel. Paving Aggregate—Vary greatly as to grade, quality, type, and composition; general types suitable for bituminous construction can be classified as: Crushed Stone, Gravel, Sand, Slag, Shell, Mineral Dust. Pebbles—Rock fragments of small or moderate size which have been more or less rounded by erosional processes. Pitrun—Natural gravel deposits; may contain some sand, clay or silt. Portland Cement—Product obtained by pulverizing clinker consisting essentially of hydraulic calcium silicates to which no additions have been made subsequent to calcination other than water or untreated calcium sulfate, except that additions not to exceed 1 percent of other materials may be interground with clinker at option of manufacturer, provided such materials have been shown to be not harmful. Riprap—Riprap as used for facing dams, canals, and waterways is normally a coarse, grade material. Typical general specifications would call for a minimum 160 lb./ft3 (2563 kg/m3) stone, free of cracks and seams with no sand, clay, dirt, etc. 244


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Sand—Standard classification of soil or granular material 3 8” (9.52mm) sieve and almost entirely passing passing the ⁄ the No. 4 (4.76mm) sieve and predominantly retained on the No. 200 (74 micron) sieve. Sand Clay (Road Surface)—Surface of sand and clay mixture in which the two materials have been blended so their opposite qualities tend to maintain a condition of stability under varying moisture content. 3 8” mateSand, Manufactured—Not natural occurring sand, - ⁄ 3 8” material. rial made by crushing + ⁄

Sandstone—Essentially rounded grains of quartz, with or without interstitial cementing materials, with the larger grains tending to be more perfectly rounded than the smaller ones. The fracture takes place usually in the cement leaving the grains outstanding. Scalp Rock—Rock passed over a screen and rejected— waste rock. Screenings—Broken rock, including dust, or size that will pass through 1/2” to 3/4” screen, depending upon character of stone. Sedimentary—Rocks formed by the deposit of sediment. Settling Rock—An enlargement to permit the settlement of debris carried in suspension, usually provided with means of ejecting the material collected. Shale—Material composed essentially of silica and alumina with a more or less thinly laminated structure imparted by natural stratification of extremely fine sediments together with pressure. Shell Aggregate—Applies to oyster, clam shells, etc., used for road surfacing material; shells are crushed to size but generally must be blended with other fine sands to produce specification gradation. Sieve—Test screens with square openings. Slag—By-product of blast furnace; usually makes good paving material, can be crushed into most any gradation; most are quite porous. Slates—Rocks, normally clayey in composition, in which pressure has produced very perfect cleavage; readily split into thin, smooth, tough plates. 245


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Slope Angle—The angle with the horizontal at which a particular material will stand indefinitely without movement. Specific Gravity—The ratio of the mass of a unit volume of a material at a stated temperature to the mass of the same volume of a gas-free distilled water at the same temperature. Stone—Any natural rock deposit or formation of igneous, sedimentary and/or metamorphic origin, either in original or altered form. Stone-Sand—Refers to product (usually less than 1/2” in diameter) produced by crushing of rock; usually highly processed, should not be confused with screenings. Stratum—A sheet-like mass of sedimentary rock or earth of one kind, usually in layers between bed of other kinds. Sub-Grade—Native foundation on which is placed road material or artificial foundation, in case latter is provided. Sub-Soil—Bed or earth immediately beneath surface soil. Tailings—Stones which, after going through crusher, do not pass through the largest openings on the screen. Top-Soil (Road Surface)—A variety of surfacing used principally in southeastern states, being stripping of certain top-soils containing natural sand-clay mixture. When placed on road surface, wetted and puddled under traffic, it develops considerable stability. Trap—Includes dark-colored, fine-grained, dense igneous rocks composed of ferro-magnesian minerals, basic feldspars, and little or no quartz; ordinary commercial variety is basalt, diabase, or gabbro. Viscosity—The measure of the ability of a liquid or solid to resist flow. A liquid with high viscosity will resist flow more readily than a liquid with low viscosity. Voids—Spaces between grains of sand, gravel or soil that are occupied by water or air or both. Weir—A structure for diverting or measuring the flow of water.

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NOTES

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NOTES:

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CONTACT INFORMATION KPI

1

700 West 21st Street Yankton, SD 57078 Main — 800-668-2579 Service — 800-542-9311 Parts — 800-766-9793 E-mail — [email protected] 2

JCI 86470 Franklin Blvd Eugene, OR 97405 Main — 800-314-4656 Service — 866-875-4058 Parts — 888-474-0115 E-mail — [email protected]

3

ASTEC MOBILE SCREENS 2704 West LeFevre Road Sterling, IL 61081

4

Main —815-626-6374 Fax — 815-626-6430 www.kpijci.com 5

NOTE: SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Because KPI-JCI and Astec Mobile Screens may use in its catalog and literature, field photographs of their products which may have been modified by the owners, products furnished by KPI-JCI and Astec Mobile Screens may not necessarily be as illustrated therein. Also, the continuous design progress makes it necessary that specifications be subject to change without notice. All sales of the products of KPI-JCI and Astec Mobile Screens are subject to the provisions of their standard warranties. KPI-JCI and Astec Mobile Screens do not warrant or represent that their products meet any federal, state, or local statutes, codes, ordinances, rules, standards or other regulations, including OSHA and MSHA, covering safety, pollution, electrical, wiring, etc. Compliance with these statutes and regulations is the responsibility of the user and will be dependent upon the area and the use to which the product is put by the user. In some photographs, guards may have been removed for illustrative purposes only. This equipment should not be operated without all guards attached in their normal position. Placement of guards and other safety equipment is often dependent upon the area and the use to which the product is put. A safety study should be made by the user of the application, and, if required, additional guards, warning signs, and other safety devices should be installed by the user, wherever appropriate before operating the products.

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Facts Figures Book

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