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FOURTH EDITION © KPI/JCI 3.5M pg 10/11 Printed in U.S.A. KPI-JCI & 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 remediation industries. KPI-JCI & 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 & Astec Mobile Screens does not represent the 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 & Astec Mobile Screens are subject to the provisions of their standard warranty. All specifications are subject to change without notice.
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Page 1: Facts Figures Book

FOURTH EDITION

© KPI/JCI 3.5M pg 10/11 Printed in U.S.A.

KPI-JCI & Astec Mobile Screens is aworldwide and industry leader for bulkmaterial handling and processingequipment including; conveyors, screeningplants, pugmill plants, sand and aggregatewashing/classifying systems and all typesof mobile, portable and stationaryaggregate processing plants for theaggregate, recycle and remediationindustries.

KPI-JCI &Astec Mobile Screens has madeevery effort to present the informationcontained in this booklet accurately.However, the information should be ageneral guide and KPI-JCI & Astec MobileScreens does not represent theinformation as exact under all conditions.Because of widely varying field conditionsand characteristics of material processed,information herein covering productcapacities and gradations produced areestimated only.

Products of KPI-JCI & Astec MobileScreens are subject to the provisions oftheir standard warranty. All specificationsare subject to change without notice.

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2

FORWARDAggregate production is based on mathematicalrelationships, volumes, lengths, widths, heights,and speeds. Because of widely varying fieldconditions and characteristics of materialprocessed, information herein relating tomachine capacities and gradations produced areestimates only. Much of this data of specialinterest to producers and their employees hasbeen included in this valuable booklet. We atKPI-JCI & Astec Mobile Screens hope you findthis resource a valuable tool in your organizationand operations.

Count on us to be your supplier for all youraggregate, recycle, and classifying needs.

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RELATIVEWORLDPRODUCTION

BYVALUE

Sandandgravel,andcrushedstone,are

thenumberoneandtworankedmineral

resource(exclusiveofenergyresources)

worldwideintermsofbothamount

andvalue.

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USGS

FIGURENO.1

6

5

4

3

2

1

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TABLE OF CONTENTSAngle of Repose/Surcharge. . . . . . . . . . . . . . . . . . . . . . . . . . 157Autogenous Crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72,79Belt Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Blade Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-98Capacity

Belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Cone crushers

Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 36-54LS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35,55-62

Feeders

Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Reciprocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Vibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Horizontal Shaft Impactor (HSI)

Andreas style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 31-32New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . 28, 29-30

Jaws

Legendary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23-25Vanguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 26-27

Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-94Roll Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-70Screens

Screen Area Calculations (VSMA) . . . . . . . . . . . . . . . . . . 144Stockpile

Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Extendable stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . 71-79Classifying

Controls (Spec-Select I, II and III) . . . . . . . . . . . . . . . . . 116-117Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Pipes, Velocity Flow and Friction Loss . . . . . . . . . . . . . . . . . . 112Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Weir Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115, 181

Coarse Material Washing . . . . . . . . . . . . . . . . . . . . . . . . . . 92-98Combo (Multi-Slope) Screens . . . . . . . . . . . . . . . . . . . . 141-143Cone Crushers

Kodiak Plus Series . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 36-54LS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 55-62

Conveyors, Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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Belt speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-155, 159Recommended by material . . . . . . . . . . . . . . . . . . . . . . . 155Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Capacity, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149-150Horsepower requirements . . . . . . . . . . . . . . . . . . . . . . . 157-158Idler classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148Incline bulk materials, recommended. . . . . . . . . . . . . . . . . . . 146Models, sizes and selections . . . . . . . . . . . . . . . . . . . . . 160-168

CrushersCones

Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 36-54LS Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 55-62

Horizontal Shaft Impactors (HSI)

Andreas style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 31-32New Holland style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-30

Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-27Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-70Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . 71-79

Crusher notesKodiak and LS Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Vertical Shaft Impactor (VSI) . . . . . . . . . . . . . . . . . . . . . . . 72, 79

DataAngle of repose – surcharge . . . . . . . . . . . . . . . . . . . . . . . . . 152Belt carrying capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Belt speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155,159

Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Elevation, conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . 149-150Horsepower requirements . . . . . . . . . . . . . . . . . . . . . . . . 157-58Idler classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148Incline, bulk materials, recommended . . . . . . . . . . . . . . . . . . 146Stockpile

Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Extendable stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Weights, common materials. . . . . . . . . . . . . . . . . . . . . . . . . . 191Weir flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115,181

Data, Industry Terms and Definitions. . . . . . . . . . . . . . 208-214Dredge, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178Electric motors and wiring . . . . . . . . . . . . . . . . . . . . . . . 173-177Generator sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Pipes, velocity flow and friction loss. . . . . . . . . . . . . . . . 179-180Railroad ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Riprap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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Spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 182-185Weights and measurers . . . . . . . . . . . . . . . . . . . . . . . . . 186-192

Definitions and Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 208-214Feeder Capacities

Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Reciprocating plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Vibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fine Material Washing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 99-104FM (Fineness Modulus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91General Information on the Aggregate Industry . . . . . . 3, 8-11Gradations

Aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15, 86-87ASTM C-33, C-144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-90Gravel, typical deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Horizontal Shaft Impactors (HSI)

Andreas style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 31-32New Holland style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-30

Jaw Crushers, Peak to Peak (CSS) . . . . . . . . . . . . . . . . . . 25,27Kodiak series cone crushers . . . . . . . . . . . . . . . . . . . . 35, 36-54Limestone, typical quarry run . . . . . . . . . . . . . . . . . . . . . . . . . . 15LS series cone crushers . . . . . . . . . . . . . . . . . . . . . . . 35, 55-62Roll crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-70Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . 71-79Washing, classifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-119

Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Horizontal Shaft Impactors (HSI)

Andreas style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 31-32New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 29-30

Horsepower RequirementsConveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157-158Horizontal Shaft Impactors (HSI)

Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Jaw Crushers (Peak to Peak) . . . . . . . . . . . . . . . . . . . . . . 25, 27Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Roll Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-68Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . . . . 73

Incline screensKPI-JCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-122, 126-135

Jaw Crushers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-27Kodiak Plus Cone crusher series . . . . . . . . . . . . . . . . 35, 36-54Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-94LS Cone crusher series . . . . . . . . . . . . . . . . . . . . . . . . 35, 55-62

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Peak to Peak Jaw crusher settings . . . . . . . . . . . . . . . . . 25, 27Pugmills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169-170Roll crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-70Screening and Washing Plants . . . . . . . . . . . . . . . . . . . 118-119Screens, calculating area VSMA . . . . . . . . . . . . . . . . . . . . . 144Screens, Types

Horizontal . . . . . . . . . . . . . . . . . . . . . . 123-124, 126, 136-140Incline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-122, 126,135Multi-Slope (Combo). . . . . . . . . . . . . . . . . . . 124-125, 141-143Sieve sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-91

SE (Sand Equivalent test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Sieve sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13Spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 182-185Stockpile

Angle of Repose/Surcharge. . . . . . . . . . . . . . . . . . . . . . . . . . 157Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Extendable Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . 208-214Track Mounted Plants

Fast Trax® Horizontal Shaft Impactor (HSI) Plants . . . . . . . . . . 80Fast Trax® Jaw Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Fast Trax® Cone Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Fast Trax® Screen Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Typical Gradation CurveGravel Deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Limestone Quarry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Vertical Shaft Impact crushers (VSI). . . . . . . . . . . . . . . . . 71-79Washing Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-85

ASTM C-33, C-144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-90Blade Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-98Classifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-117Coarse material washing . . . . . . . . . . . . . . . . . . . . . . . . . . 92-98Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116-117Dredge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178Fine material washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 99-104Fineness Modulus (FM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-94Sand Equivalent test (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Screening and Washing plants. . . . . . . . . . . . . . . . . . . . 118-119

Weights and Measures . . . . . . . . . . . . . . . . . . . . . . . . . . 186-207World Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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GENERAL INFORMATION ON THE INERTMINERAL (AGGREGATE) INDUSTRY

Modern civilization is based on the use of inert miner-als for concrete and asphaltic products. In truth,aggregate production is the largest single extractiveindustry in the United States. In excess of 2.8 billiontons of sand, gravel and crushed rock are producedannually. Because aggregates play such a vital role inthe continuing growth of the nation and the world,demand for all types can be expected to increase sub-stantially in the years ahead.

There is great romance about these commonplaceminerals; the earth sciences tell us a compelling storyof the evolution of the earth’s mantle and its mineralswhich man has found so valuable to the civilizingprocesses on his planet. Since the earliest Ice Age,erosion of the continental rock by earth, wind, rain andfire have resulted in fractions being carried down themountains by wind and water, the grains settling in analmost natural grading process. Other natural eventssuch as floods and upheavals caused rivers andstreams to change courses, burying river beds thathave become high production sand and gravel opera-tions in our time. Evaporation, condensation,precipitate and chemical actions, percolation andfusions have formed other rock materials that havebecome valuable aggregates in modern times.Advancements in geology and technology aid theindustry in its progress to greater knowledge aboutthese building blocks of all ages and civilizations.

Locating these minerals has become much easier,too—and just in time as recently the nation hasacknowledged the state of neglect of hundreds of thou-sands of miles of state and county roads. The massiveInterstate Program has dominated the expenditure ofroad - building funds at the expense of these ruralhighways, so that today there are vast amounts ofrepair, reclamation and replacement of roads to bedone. And, of course, locating nearby sources ofroadbed materials wherever possible will affect theeconomy of construction…and, in some cases, eventhe kind of construction as well.

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Rapid field investigations for possible sources of min-erals have been made very simple and relativelyinexpensive by the use of portable seismic instrumentsand earth resistivity meters. The latter are especiallyeffective in locating sand, gravel and ground water bymeasuring the inherent electrical characteristics ofeach. Briefly, an alternating current is applied acrosselectrodes implanted at known spacings in the surfacesoil; the potential drop of the current between the elec-trodes indicates whether the subsurface geologyincludes any high resistance areas, indicating sand,gravel or water. Another tool, the portable seismicinstrument is used to measure the velocity of energytransmitted into the earth as deep as 1,000 feet. Thevelocity of the energy wave’s travel through the sub-surface geologic structure indicates the density orhardness of each layer or strata. For example, thevelocity of topsoil may be 3,000 feet per sec. whilelimestone, granite and other potentially useful inertmaterials may have velocities beyond 12,000 feet persec. Thus, where the occurrence of aggregate mater-ial is not always convenient to the shortest haul routesor major population centers, locating and utilizing themhave benefitted greatly by modern technology.

CLASSES OF AGGREGATESThere are two main classes of aggregates.1. Natural aggregates in which forces of naturehave produced formations of sand and graveldeposits. These may include silts, clays or otherforeign materials which are difficult to reject. Fur-ther, gradations may be quite different thanthose required for commercial sales. To meetsuch requirements, it becomes necessary toprocess or beneficiate natural aggregatedeposits.

2. Manufactured aggregates are obtained fromdeposits or ledges of sedimentary rock (formedby sediments) or from masses of igneous rock(formed by volcanic action or intense heat).These are blasted, ripped or excavated and thencrushed and ground to specified gradations.These deposits, too, may include undesirablematerials such as shales, slates or bodies ofmetamorphic or igneous rock. Such deleteriousmaterials must be removed in the processingoperations.

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PROCESSING OF AGGREGATESMuch of the equipment used in the processing of rawaggregates has been adapted from other mineral pro-cessing techniques and modified to meet the specificrequirements of the crushed stone, sand and gravelindustry. Other types of equipment have been intro-duced to improve efficiency and final product. Theequipment is classified in four groups.1. Reduction equipment, jaw, cone, roll, gyratory,impact crushers and mills; these reduce materi-als to required sizes or fractions.

2. Sizing equipment: Vibratory and grizzly screensto separate the fractions in varying sizes.

3. Dewatering equipment: Sand Sorters, Log Wash-ers, Sand and Aggregate preparation and Fineand Coarse recovery machines.

4. Sorting equipment. This can include variouskinds of feeder traps and conveyor arrange-ments to transfer, stockpile or hold processedaggregates.

As to method, there are two types of operations atmost sand and gravel pits and quarry operations. Theyinclude: (a) dry process; here the material is excavatedby machines or blasted loose, and is hauled to a pro-cessing plant without the use of water, and (b) wetprocess: This may involve pumping (dredge pumps) orexcavation (draglines) of the aggregate material from apit filled with water. The material enters the processingoperation with varying quantities of water.

The ideal gradation is seldom, if ever met in naturallyoccurring sand or gravel. Yet the quality and control ofthese gradations is absolutely essential to the worka-bility and durability of the end use.

The aggregate has three principal functions:1. To provide a relatively cheap filler for cementingor asphaltic materials.

2. To provide a mass of particles that will resist theaction of applied loads, abrasion, percolation ofmoisture, and water.

3. To keep to a minimum the volume changesresulting from the setting and hardening processand from moisture changes.

Page 11: Facts Figures Book

11

The influence of the aggregate on the resulting productdepends on the following characteristics:1. The mineral character of the aggregate asrelated to strength, elasticity, and durability.

2. The surface characteristics of the particles, par-ticularly as related to workability and bondingwithin a hardened mass.Aggregate with rough surfaces or angularshapes does not place or flow as easily into theforms as smooth or rounded grains.

3. The gradation of the aggregates, particularly asrelated to the workability, density, and economyof the mix.

Of these characteristics, the first two are self-explana-tory and inherent to a particular deposit. In some casesan aggregate can be upgraded to an acceptable prod-uct by removing unsound or deleterious material, usingbenefication processes.

Gradation, however, is a characteristic which can bechanged or improved with simple processes and is theusual objective of aggregate preparation plants.

Page 12: Facts Figures Book

12

100

80Nos

100-

4si

eves

Nos10

0-4

siev

es

Nos

4-1.

5in

. sie

ves

Nos

4-1.

5in

. sie

ves

60

40

20

0100 50 30 16 8 4 13/4

3/81/2 11/2

Nos10

0-4

siev

es

Nos

4-1.

5in

. sie

ves

SIEVE ANALYSIS ENVELOPEPercent passing by weight

Standard sizes of square-mesh sieves

Curves indicate the limits specified in ASTM for fine andcoarse aggregate

FIGURE NO. 2

EXAMPLE OF ALLOWABLE GRADATIONZONE IMPORTANCE OF GRADATION—

CONCRETE

To improve workability of concrete, either the amountof water or the amount of fine particles must beincreased. Since the water-to-cement ratio is governedby the strength required in the final cured concrete,any increase in the amount of water would increasethe amount of cement in the mix. Since cement costsare much greater than aggregate, it is evident thatvarying the gradation is more economical. Most of theformula used for proportioning the components of theconcrete have been worked out as the results of actualexperimentation. They are based, however, on twofundamentals.1. To obtain a sound concrete, all voids must befilled either with fine aggregates or cementpaste.

2. To obtain a sound concrete, the surface of eachaggregate particle should be covered withcement paste.

An ideal mix is a balance between saving on cementpaste by using fine aggregates to fill the voids, and theadded paste required to cover the surfaces of theseadditional aggregate particles.

Page 13: Facts Figures Book

13

ACTUAL GRADATION

The ideal gradation is seldom, if ever, met in naturally-occurring sand or gravel. In practice, the quality of thegradation of the aggregate, the workability of the con-crete, cement and asphalt requirements must bebalanced to achieve strength and other qualitiesdesired, at minimum total cost.

Sizing of material larger than No. 8 sieve is best andmost economically done by the use of mechanicalscreens of various types, either dry or wet. In actualpractice, however, the division between coarse aggre-gates which require different equipment for sizing, isset at No. 4 sieve, (Fig. 3).

Tables have been published to facilitate these calcula-tions, and they are based on the maximum size of thecoarse aggregate which can be used for the specifictype of construction planned.

Percent Weight RetainedSieveNo.

Allowable Sample Tested

Cumulative Indiv- Cumul-Min. Max. dual tive

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

Page 14: Facts Figures Book

14

TYPICAL GRADATION CURVESFOR GRAVEL DEPOSITS

#200

#100#80

#60

#50#40

#30

#20

#16

#10#8

#4

/4

/8

/4

11 /4

1 /2

2

3

456

/2

6.35

9.53

19.0

25.431.838.1

50.8

76.2

102127152

12.7

100 80 60 40 20 0

SIEVE ANALYSISmminches % RETAINED

0 20 40 60 80 100

SIE

VE

SIZ

E

% PASSING

KEY:35/65 Heavy Gravel50/50 Deposit65/35 Heavy Sand

1

1

3

1

1

3

Page 15: Facts Figures Book

15

TYPICAL GRADATION CURVESFOR LIMESTONE QUARRY RUN

#8

#4

1/4

3/8

1/2

3/4

1

11/2

2

21/2

3

4

5

678

1012

6.35

9.53

12.7

19.0

25.4

38.1

50.8

63.5

76.2

102

127

152178203

254305

100 80 60 40 20 0

0 20 40 60 80

mminches % RETAINED

SIEVE ANALYSIS

100

% PASSING

SIE

VE

SIZ

E

KEY:Top Size 30" - 36" CoarseTop Size 24" - 27" AverageTop Size 18" - 21" Fine

Page 16: Facts Figures Book

16

APRON FEEDERS

Particularly suited for wet, sticky materials, the ApronFeeder provides positive feed action while reducingmaterial slippage. Feeder construction includes heavy-duty and extra-heavy-duty designs depending uponthe application.

Page 17: Facts Figures Book

17

STAN

DAR

DH

OPP

ERAP

PRO

XIM

ATE

CAPA

CITI

ES—

APR

ON

FEED

ERS

6Ft

1.83

m8Ft.

2.44

m10

Ft.

3.05

m12

Ft.

3.66

m14

Ft.

4.27

m

Width

Yd.3

m3

Yd.3

m3

Yd.3

m3

Yd.3

m3

Yd.3

m3

30"(

762mm)A

pron

Feed

erWith

outE

xten

sion

2.1

1.6

3.2

2.4

4.3

3.3

5.4

4.1

——

30"(

762mm)A

pron

Feed

erWith

Extens

ion

3.3

2.5

5.8

4.4

8.3

6.4

10.8

8.2

——

36"(

914mm)A

pron

Feed

erWith

outE

xten

sion

2.4

1.8

3.6

2.8

4.8

3.7

6.0

4.6

7.2

5.5

36"(

914mm)A

pron

Feed

erWith

Extens

ion

3.6

2.8

6.3

4.8

9.0

6.9

11.7

8.9

14.5

11.1

42"(

1067

mm)A

pron

Feed

erWith

outE

xten

sion

2.6

2.0

3.9

3.0

5.3

4.0

6.6

5.0

7.9

6.0

42"(

1067

mm)A

pron

Feed

erWith

Extens

ion

3.9

3.0

6.8

5.2

9.7

7.4

12.6

9.6

15.6

11.8

48"(

1219

mm)A

pron

Feed

erWith

outE

xten

sion

——

4.4

3.4

5.8

4.4

7.3

5.6

8.8

6.7

48"(

1219

mm)A

pron

Feed

erWith

Extens

ion

——

7.4

5.6

10.5

8.0

13.6

10.4

16.7

12.8

Mod

elSize

Type

ofAp

prox

.Cap

acity

*Hop

perS

ize

Hop

perC

apacity

Weigh

t

Num

ber

in.

mm

Service

at60

RPM

Ft.S

q.MetersSq

.Cu

.Yards

Cu.M

eters

(With

Hop

per)

25RP

2461

0Stan

dard

100-20

0TP

H(90

.7-1

81mt/h

)6

1.83

1.7

1.3

2050

lbs.

931kg

31RP

3076

2Stan

dard

150-30

0TP

H(13

6-27

2(m

t/h)

61.83

1.7

1.3

2165

lbs.

983kg

30RP

3076

2Heavy

Duty

150-30

0TP

H(13

6-27

2mt/h

)6

1.83

1.7

1.3

2550

lbs.

1158

kg

37RP

3691

4Stan

dard

215-43

0TP

H(19

5-39

0mt/h

)7

2.14

2.6

1.99

3175

lbs.

1441

kg

36RP

3691

4Heavy

Duty

215-43

0TP

H(19

5-39

0mt/h

)7

2.14

2.6

1.99

3950

lbs.

1793

kg

42RP

4210

67Heavy

Duty

300-60

0TP

H(27

2-54

4mt/h

)7

2.14

2.6

1.99

4710

lbs.

2136

kg

REC

IPR

OCA

TIN

GPL

ATE

FEED

ERS

NO

TE:*

Ran

geis

fortyp

eof

feed

from

dampsticky

todrymaterial.

Page 18: Facts Figures Book

18

PanTravel

(Ft.pe

rMin.)

Yds3

Tons

Yds3

Ton

Yds3

Tons

Yds3

Tons

Yds3

Tons

Yds3

Tons

1055

7480

108

109

147

143

192

222

300

320

432

1583

112

120

162

164

222

214

289

333

450

480

648

2011

014

816

021

621

829

428

438

444

460

065

086

425

138

186

200

270

273

369

357

482

555

750

800

1080

3016

522

324

032

432

744

242

757

766

790

096

012

9635

193

260

280

378

382

516

500

673

778

1050

1120

1512

4022

029

632

043

243

658

857

276

888

812

0012

8017

28

30"W

ide

36"W

ide

42"W

ide

48"W

ide

60"W

ide

72"W

ide

PanTravel

(meterspe

r(m

inute)

m3

mt

m3

mt

m3

mt

m3

mt

m3

mt

m3

mt

3.05

4267

6198

8313

310

917

417

027

224

539

24.57

6310

292

147

125

201

164

262

254

408

367

588

6.10

8413

412

219

616

726

721

734

833

954

448

978

47.62

105

169

153

245

209

335

273

437

424

680

611

908

9.14

126

202

183

293

250

401

326

523

510

816

734

1176

10.67

147

236

214

343

292

468

382

610

594

953

856

1372

12.19

168

269

245

392

333

533

437

697

679

1089

978

1568

.762

mWide

.914

mWide

1.07

mWide

1.22

mWide

1.52

mWide

1.83

mWide

NO

TE:C

onside

rablevaria

ncewill

alwaysbe

enco

unteredwhe

ncalculatingthecapa

citie

sof

feed

ers.

Usu

ally,e

xperienc

eis

thebe

stgu

ideto

wha

tafeed

erwill

hand

leun

derg

iven

cond

ition

sof

material,rate

oftravel

ofthefeed

erpa

ns,a

ndde

pthof

load

ing.

Thetableab

oveis

basedon

ade

pthof

materiale

qual

toha

lfthefeed

erwidth,a

ndtons

areba

sedon

materialw

eigh

ing2,70

0po

unds

perc

u.yd

.Afeed

ingfactor

of.8

hasbe

enintrod

uced

toco

mpe

nsateforv

oids

,resistan

ceto

flow,e

tc.T

hisfactor,too

,will

vary

with

thetype

ofmateriala

ndits

cond

ition

whe

nfed.

Thefollo

wingform

ulacanbe

used

tocalculatetheap

prox

imatecapa

city

incu

bicyardsof

afeed

erof

givenwidth

whe

rethefeed

ingfactor

isde

term

ined

tobe

othe

rtha

n.8:

Cu.Y

dspe

rHr.=2.22

(dxw

xsxf);w

here

d=de

pthof

load

onfeed

er,infeet:

s=rate

ofpa

ntravel,infeet

perm

inute;

w=width

offeed

er,infeet;

f=feed

ingfactor.

Toco

nvertc

u.yd

s.to

tons

;multip

lycu

.yds

.by1.35

.

APPR

OXI

MAT

EPE

RH

OU

RCA

PACI

TIES

OF

APR

ON

FEED

ERS

ACCO

RD

ING

TOW

IDTH

Page 19: Facts Figures Book

19

VIBRATING FEEDERS

Designed to convey material while separating fines,Vibrating Feeders provide smooth, controlled feedrates to maximize capacity. Grizzly bars are tapered toself-relieve with adjustable spacing for bypass sizing.Feeder construction includes heavy-duty deck platewith optional AR plate liners. Heavy-duty spring sus-pension withstands loading impact and assistsvibration.

CAPACITY FACTOR “C” FACTOR “C”SIZE OF OPENING (IN.) PERFORATED PLATE GRIZZLY BARS

2 4.1 6.13 5.4 8.14 6.7 10.05 8.6 15.06 9.8 17.27 10.9 19.18 11.6 23.29 12.5 25.010 13.5 27.0

SCALPING SCREEN SIZING FORMULA

MODIFYING FACTOR “O” FOR PERCENTOF OVERSIZE IN THE FEED

Scalping Area = Tons / hour of undersize in the feed

Capacity per square feet (“C”) x modifying factors “O” and “F”

% FACTOR10 1.0520 1.0130 .9840 .9550 .9060 .8670 .8080 .7085 .6490 .55

MODIFYING FACTOR “F” FOR PERCENTPASSING HOLES HALF-SIZE OF OPENING

% FACTOR10 .5520 .7030 .8040 1.0050 1.2060 1.4070 1.8080 2.2085 2.5090 3.00

Page 20: Facts Figures Book

20

30" (.76m) 36" (.91m) 42" (1.07m) 50" 1.27m) 60" (1.5m)WIDE WIDE WIDE WIDE WIDE

RPM TPH mt/h TPH mt/h TPH mt/h TPH mt/h TPH mt/h

600 828 754650 623 568 898 818700 315 287 473 431 671 611 967 881750 270 246 337 307 507 462 720 656 1035 943800 290 264 360 328 541 493 767 698850 305 278 382 348 575 524900 325 296 404 368 609 555950 345 314 427 389 642 5851000 365 332

VIBRATING FEEDERS—APPROXIMATE CAPACITY*

CAPACITY MULTIPLIERS FOR VARIOUS FEEDER PANMOUNTING ANGLES FROM 0° TO 10° DOWN HILL—

ALL VIBRATING FEEDERS

STANDARD HOPPER APPROXIMATE CAPACITIESVIBRATING 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 begreater 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 Feeder Size Yds.3 M3

30" x 12' ( 762mm x 3.7m) Without Extension 5.5 4.230" x 12' ( 762mm x 3.7m) With Extension 7.2 5.536" x 14' ( 914mm x 4.3m) Without Extension 7.2 5.536" x 14' ( 914mm x 4.3m) With Extension 12.6 9.636" x 16' ( 914mm x 4.9m) Without Extension 8.2 6.336" x 16' ( 914mm x 4.9m) With Extension 14.4 11.042" x 15' (1067mm x 4.6m) Without Extension 9.0 6.942" x 15' (1067mm x 4.6m) With Extension 18.0 13.842" x 17' (1067mm x 5.2m) Without Extension 10.2 7.842" x 17' (1067mm x 5.2m) With Extension 20.4 15.642" x 18' (1067mm x 5.5m) Without Extension 10.0 8.242" x 18' (1067mm x 5.5m) With Extension 21.6 16.542" x 20' (1067mm x 6.2m) Without Extension 12.0 9.242" x 20' (1067mm x 6.2m) With Extension 24.0 18.450" x 16' (1270mm x 4.9m) Without Extension 11.0 8.450" x 16' (1270mm x 4.9m) With Extension 21.6 16.550" x 18' (1270mm x 5.5m) Without Extension 12.6 9.650" x 18' (1270mm x 5.5m) With Extension 24.3 18.650" x 20' (1270mm x 6.1m) Without Extension 14.0 10.750" x 20' (1270mm x 6.1m) With Extension 27.0 20.660" x 24' (1524mm x 7.3m) Without Extension 19.6 15.060" x 24' (1524mm x 7.3m) With Extension 43.0 32.9

Page 21: Facts Figures Book

21

BELT FEEDER CAPACITY (TPH)

Belt Speed FPMH (inches) 10 20 30 40 50 608 30 60 90 120 150 180

9 34 68 101 135 169 203

10 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

24"B

ELT

FEED

ER(W

=18

")30

"BEL

TFE

EDER

(W=

24")

36"B

ELT

FEED

ER(W

=30

")42

"BEL

TFE

EDER

(W=

36")

NOTE: Capacities based on 100 lb./cu. ft. material

TPH = 3 x H (in.) x W (in.) x FPM

144

Page 22: Facts Figures Book

22

JAW CRUSHING PLANTS

Rubber Tire Mounted

Track Mounted

Stationary

Page 23: Facts Figures Book

23

LEGE

NDAR

YJAW

LEGE

NDAR

YJAW

Self-

Align

ingSp

heric

alRo

llerB

earin

gs

Forg

edEc

cent

ricSh

aft

Optio

nalO

ilLu

brica

tionS

yste

m

Bear

ingHo

using

Barre

lPro

tecto

rPlat

e

Heav

y-Du

tyFly

whe

el

Reve

rsibl

eJa

wDi

es

Togg

leSe

ats

Single

SideP

late

Base

Cons

tructi

on

Togg

lePl

ate

Tens

ionRo

d

Shim

Adjus

tHy

drau

lic/S

himCS

SAd

justm

ent

Key

and

Heel

Plat

es

Heav

y-Du

tyCa

stPi

tman

Page 24: Facts Figures Book

24

The chart on this page is particularly useful in determiningthe percentages of various sized particles to be obtainedwhen two or more crushers are used in the same set up. It isalso helpful in determining necessary screening facilities formaking size separations. Here is an example designed tohelp show you how to use the percentage charts:

To determine the amount of material passing 11⁄4" (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 lineto 11⁄4" (31.8 mm). The horizontal line shows 39% passing…or61% retained.

APPROXIMATE GRADATIONS AT PEAK TO PEAK CLOSED SIDE SETTINGSTest Test

Sieve 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 31⁄2" 4" 5" 6" 7" 8" Sieve

Sizes 19 25.4 31.8 38.1 50.8 63.5 76.2 89.1 102 127 152 178 203 Sizes

(in.) mm mm mm mm mm mm mm mm mm mm mm mm mm (mm)

12" 100 98 95 305

10" 100 97 95 90 254

8" 100 96 92 85 75 203

7" 100 97 92 85 76 65 178

6" 100 98 93 85 74 65 53 152

5" 100 97 95 85 73 62 52 40 127

4" 100 96 90 85 70 56 45 38 28 102

3" 100 93 85 75 65 50 38 32 27 23 76.2

21⁄2" 100 95 85 73 62 52 38 31 24 22 17 63.5

2" 100 96 85 70 55 47 39 28 24 20 17 13 50.8

11⁄2" 100 93 85 67 49 39 33 27 21 18 15 13 10 38.1

11⁄4" 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

3⁄4" 66 49 39 28 21 18 15 13 11 9 8 6 5 19.0

1⁄2" 41 29 24 19 14 12 10 9 7 6 6 5 4 12.7

3⁄8" 28 21 18 14 11 9 8 7 5 5 5 4 3 9.53

1⁄4" 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

Values Are Percent Passing

JAW CRUSHERSAPPROXIMATE JAW CRUSHERS GRADATION—OPEN CIRCUIT

Page 25: Facts Figures Book

25

LEG

EN

DA

RY

JAW

CRU

SHER

S—H

OR

SEPO

WER

REQ

UIR

EDAN

DAP

PRO

XIM

ATE

CAPA

CITI

ESIN

TPH

SIZE

3 ⁄4"1"

11 ⁄4"11 ⁄2"

2"21 ⁄2"

3"31 ⁄2"

4"5"

6"7"

8"9"

10"

11"

12"

1925

3238

5164

7689

102

127

152

178

203

228

254

279

304

Elec

tD

iese

lm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

m

1016

1525

1012

1419

2428

1024

2540

1518

2229

3644

1036

4060

2227

3344

5567

1047

110

2936

4459

7389

1524

4060

3645

5463

7215

3675

110

5468

8195

109

136

1654

125

175

8110

212

214

216

320

418

3060

9061

7486

9812

320

3610

014

010

912

413

915

618

724

3610

015

012

313

615

317

120

523

927

321

4812

517

014

516

518

620

724

826

4915

019

016

518

821

123

528

228

5420

025

021

324

126

832

337

843

330

4215

019

020

022

326

831

335

731

6320

025

029

033

037

045

053

061

069

033

5020

025

027

530

235

040

746

552

235

4620

025

027

530

235

040

746

552

242

4825

031

032

437

643

850

056

262

568

875

287

5

HP

Req

uire

d(M

inim

um)

APPR

OXI

MAT

ECA

PACI

TIES

ATPE

AKTO

PEAK

CLO

SED

SID

ESE

TTIN

GS

(IN

TPH

)*

*****

***

***

***

*** ** ** ** ** NO

TE:

*Based

onmaterialw

eigh

ing2,70

0lbs.

perc

ubic

yard.C

apacity

may

vary

asmuc

has

±25%

.**La

rger

setting

smay

beob

tained

with

othe

rtha

nstan

dard

togg

leplate…

cons

ultF

actory.

***Leg

enda

ryjaw

sizesthat

areno

long

erstan

dard

prod

uctio

nmod

els.

Page 26: Facts Figures Book

26

Forg

ed11 / 2

”St

roke

Ecce

ntric

Shaf

tSe

lf-Al

igning

Sphe

rical

Rolle

rBea

rings

Barre

lPro

tecto

rPlat

e

Hydr

aulic

Dual

Wed

geSy

stem

(Aut

oAd

just)

SideB

ase

Wea

rLine

rs

Low

erRe

taini

ngTip

sT o

ggle

Seat

s

Jaw

Die

Rete

ntion

Wed

ges

Bear

ingHo

using

Heav

y-Du

tyFly

whe

el

Single

SideP

late

Base

Cons

tructi

on

Auto

matic

Tens

ionRo

dAss

embly

Heav

y-Du

tyOp

enBa

ckCa

stPi

tmanVA

NGUA

RDJA

WVA

NGUA

RDJA

W

Page 27: Facts Figures Book

27

VA

NG

UA

RD

JAW

CRU

SHER

SH

OR

SEPO

WER

REQ

UIR

EDAN

DAP

PRO

XIM

ATE

CAPA

CITI

ESIN

TPH

NO

TE:*B

ased

onmaterialw

eigh

ing2,70

0lbs.

perc

ubic

yard.C

apacity

may

vary

with

thematerialc

haracteristic

s.**

Larger

setting

smay

beob

tained

with

othe

rtha

nstan

dard

togg

leplate…

cons

ultF

actory.

SIZE

3 ⁄4"1"

11 ⁄4 "11 ⁄2"

2"21 ⁄2"

3"31 ⁄2"

4"5"

6"7"

8"9"

10"

11"

12"

1925

3238

5164

7689

102

127

152

178

203

228

254

279

304

Elec

tD

iese

lm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

m

2640

125

160

140

160

180

200

240

2650

150

190

165

188

211

235

282

3055

200

250

265

300

334

402

471

528

3144

150

190

212

240

267

320

373

426

3165

200

250

265

305

372

459

530

611

692

3352

200

250

318

360

416

484

553

4450

250

310

423

492

574

654

735

816

HP

Req

uire

d(M

inim

um)

APPR

OXI

MAT

ECA

PACI

TIES

ATPE

AKTO

PEAK

CLO

SED

SID

ESE

TTIN

GS

(IN

TPH

)*

** **

Page 28: Facts Figures Book

28

HSI PLANTS

Track mounted

Rubber tire mounted Andreas style

Rubber tire mounted New Holland style

Page 29: Facts Figures Book

29

PRIMARY IMPACT CRUSHERS(New Holland Style)

Making a cubical product necessary for asphalt andconcrete specifications poses many equipmentproblems for the aggregate producer. Among theseproblems are abrasive wear, accessibility for hammermaintenance or breaker bar changes and bridging inthe crushing chamber.

Impact Crusher units are designed to help over-comeproblems faced by producers and at the same time toprovide maximum productivity for existing conditions.

Page 30: Facts Figures Book

30

PRIMARY IMPACT CRUSHERS(NEW HOLLAND STYLE)—APPROXIMATE PRODUCT

GRADATION—OPEN CIRCUITTest TestSieve SieveSizes Normal Close Normal Close Normal Close Sizes(in.) Setting Setting Setting Setting Setting Setting (mm)

6" 100 152

5" 100 97 100 127

4" 100 98 100 90 98 102

3" 96 100 89 96 75 89 76.2

21⁄2" 90 97 80 90 66 80 63.5

2" 77 89 67 77 56 67 50.8

11⁄2" 64 75 56 64 48 56 38.1

11⁄4" 57 67 50 57 43 50 31.8

1" 50 58 44 50 38 44 25.43⁄4" 41 47 37 41 31 37 19.11⁄2" 32 37 28 32 24 28 12.73⁄8" 26 30 23 26 19 23 9.531⁄4" 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

3850 4654 6064

Recommended HP Approx. Capacities*Maximum

Size Electric Diesel TPH mt/h Feed Size

3850 250-300 350-450 250-450 227-409 24"

4654 300-400 450-600 400-750 364-682 30"

6064 400-600 600-900 600-1200 545-1091 40"

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 typeof feed, adjustment of lower breaker bar, etc.

Values are percent passing

Page 31: Facts Figures Book

31

ANDREAS STYLEIMPACT CRUSHERS

These Impact Crushers are designed for recyclingconcrete, asphalt, as well as traditional aggregatecrushing applications. The Maximum PerformanceRotor (MPR) offers the mass of a solid design with theclearances of an open configuration.

Page 32: Facts Figures Book

32

100%

90%

80%

70%

60%

50%

40%

30%

20%

50 mesh 8 mesh 1" 3" 10"12"

10%

0%

APRONS:Upper @ 4"Lower @ 2"

%C

umul

ativ

eP

assi

ng

Approximate Output Gradations-Open Circuit

8000 fpm

6500 fpm

5250 fpm

FEED

ANDREAS IMPACT CRUSHERSHORIZONTAL SHAFT IMPACT CRUSHER

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

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

Min Lower/Upper Apron

Setting

Maximum Feed Size**

Size Recycle Limestone 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"

Page 33: Facts Figures Book

33

CONE CRUSHERS

Track mounted

Rubber tire mounted Kodiak Plus

Rubber tire mounted LS

Page 34: Facts Figures Book

34

KODIAK™ PLUS AND LS CONE CRUSHER NOTES1. Capacities and product gradations produced bycone crushers will be affected by the method offeeding, characteristics of the material fed, speed ofthe machine, power applied, and other factors.Hardness, compressive strength, mineral content,grain structure, plasticity, size and shape of feedparticles, moisture content, and other characteris-tics of the material also affect production capacitiesand gradations.

2. Gradations and capacities shown are based on atypical well graded choke feed to the crusher. Wellgraded feed is considered to be 90% - 100% pass-ing the closed side feed opening, 40% - 60%passing the midpoint of the crushing chamber onthe closed side (average of the closed side feedopening and closed side setting), and 0 - 10% pass-ing the closed side setting. Choke feed isconsidered to be material located 360 degreesaround the crushing head and approximately 6"above the mantle nut.

3. Maximum feed size is the average of the open sidefeed opening and closed side feed opening.

4. A general rule of thumb for applying cone crushersis the reduction ratio. A crusher with coarse styleliners would typically have a 6 to 1 reduction ratio.Thus, with a 3⁄4" closed side setting the maximumfeed would be 6 x 3⁄4 or 4.5 inches. Reduction ratiosof 8 to 1 may be possible in certain coarse crushingapplications. Fine liner configurations typically havereduction ratios of 4:1 to 6:1.

5. Minimum closed side setting may be greater thanpublished settings since it is not a fixed dimension.It will vary depending on crushing conditions, thecompressive strength of the material beingcrushed, and stage of reduction. The actual mini-mum closed side setting is that setting just beforethe bowl assembly lifts minutely against the factoryrecommended pressurized hydraulic relief system.Operating the crusher at above the factory recom-mended relief pressure will void the warranty, as willoperating the crusher in a relief mode (bowl float).

Page 35: Facts Figures Book

35

KODIAK PLUS ANDLS CONE CRUSHERS

KODIAK 300+ CONE

1400 LS Cone

Page 36: Facts Figures Book

36

KODIAK™ OPERATING PARAMETERSThe following list outlines successful operating para-meters for the Kodiak Plus line of crushers. These arenot prioritized in any order of importance.

Material1. Material with a compressive strength greater than

40,000 pounds per square inch should bereviewed and approved in advance by the factory.

2. No more than 10% of the total volume of feedmaterial is sized less than the crusher closed sidesetting.

3. The crusher feed material conforms to the recom-mended feed size on at least two sides.

4. Moisture content of material below 5%.5. Feed gradation remains uniform.6. Clay or plastic material in crusher feed is limited to

prevent the formation of compacted material or“pancakes” being created.

Mechanical1. Crusher operates at factory recommended tramp

iron relief pressures without bowl float.2. Crusher support structure is level and evenly sup-

ported across all four corners. In addition thesupport structure provides adequate strength toresist static and dynamic loads.

3. Crusher is operated only when all electrical, lubri-cation and hydraulic systems are correctlyadjusted and functioning properly.

4. Lubrication low flow warning system functions cor-rectly.

5. Lubrication oil filter functions properly and showsadequate filtering capacity on its indicator.

6. Crusher drive belts are in good condition and ten-sioned to factory specifications.

7. Crusher lubrication reservoir is full of lubricant thatmeets factory required specifications.

8. Any welding on the crusher or support structure isgrounded 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 ordeveloping cracks.

Page 37: Facts Figures Book

37

11. Crusher cone head is properly blocked prior totransport.

12. Only authorized OEM parts or factory approvedwear parts are used.

Application1. Reduction ratio limited to 6 to 1 below 1" closed

side setting and 8 to 1 above 1" closed side set-ting provided no bowl float occurs.

2. Manganese chamber configuration conforms tothe factory recommended application guidelines.

3. Crusher is operated at the factory recommendedrpm for the application.

4. Crusher feed is consistent, providing an even flowof material, centered in the feed opening, andcovering the mantle nut at all times.

5. Crusher input horsepower does not exceed fac-tory specifications.

6. Crusher discharge chamber is kept clear of mate-rial buildup.

7. If the crusher cannot be totally isolated from metalin the feed material, a magnet should be usedover the crusher feed belt.

8. Crusher is never operated at zero closed side set-ting.

Page 38: Facts Figures Book

38

KOD

IAK

200+

CON

ECR

USH

ERPR

OJE

CTED

CAPA

CITY

AND

GR

ADAT

ION

CHAR

TSProjected

OpenCircuitC

apacititesintons-per-hour

Clos

edSide

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"11⁄4"

11⁄2"

13⁄4"

2"Se

tting

(CSS

)12

.7mm

15.87mm

19.05mm

22.22mm

25.4

mm

32mm

38.1

mm

44.5

mm

50.8

mm

Gross

Throug

hput

125-16

514

0-19

516

5-22

018

0-24

522

0-32

024

0-34

526

0-36

526

0-36

527

0-38

5

Projected

ClosedCircuitC

apacititesintons-per-hour

Clos

edSide

3 ⁄8"

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"11⁄4"

Setting

(CSS

)9.52

mm

12.7

mm

15.87mm

19.05mm

22.22mm

25.4

mm

32mm

Recirc

ulating

Load

16%

20%

20%

20%

26%

28%

29%

Gross

Throug

hput

115-14

514

4-19

016

5-22

018

5-25

020

5-27

522

5-30

024

5-32

0

Net

Throug

hput

97-122

211

6-15

213

2-17

614

8-20

015

2-20

416

2-21

617

4-22

7

Minim

umclos

edside

setting

istheclos

etsetting

possible

that

does

notind

ucebo

wlfloat.

Actualminim

umclos

edside

setting

andprod

uctio

nnu

mbe

rswillvary

from

pittopita

ndareinflu

encedby

such

factorsas

nature

offeed

material,

ability

toscreen

outfines,m

anga

nese

cond

ition

,and

low

reliefs

ystem

pressu

re.

Page 39: Facts Figures Book

39

KODIAK 200+ CONE CRUSHERGRADATION CHART

Prod-uctSize

Crusher Closed Side Setting

5⁄16" 3⁄8" 7⁄16" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

7.94 9.52 11.11 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8mm mm mm mm mm mm mm mm mm mm mm mm

4" 100

31⁄2" 100 96

3" 100 95 90

23⁄4" 98 92 86

21⁄2" 100 95 88 81

21⁄4" 97 91 83 74

2" 100 94 86 76 65

13⁄4" 100 97 88 79 66 55

11⁄2" 100 95 91 80 68 56 45

11⁄4" 100 97 90 83 70 56 46 38

1" 100 99 90 82 72 58 45 36 29

7⁄8" 100 99 93 86 74 64 48 38 30 25

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

Estimated product gradation percentages at setting shown.

Page 40: Facts Figures Book

40

KODIAK 200+ MANGANESECONFIGURATION

KODIAK 200+Coarse

Chamber

Mantle: 406051XBowl Liner: 406053X

Product Range: 3⁄4" to 2"Pinion Speed: 900 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl floatoccurs then you have gone beyond the allowable reduction ratio.)

KODIAK 200+MediumChamber

Mantle: 406051XBowl Liner: 406055X

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

All Dimensions in inchesA B C

9 (228.6mm) 10 (254mm) 2 (50.8mm)

81⁄2 (215.9mm) 91⁄2 (241.3mm) 11⁄2 (38.1mm)

81⁄4 (209.5mm) 91⁄4 (234.9mm) 11⁄4 (31.7mm)

8 (203.2mm) 9 (228.6mm) 1 (25.4mm)

73⁄4 (196.8mm) 83⁄4 (222.2mm) 7⁄8 (22.2mm)

All Dimensions in inchesA B C

53⁄4 (146mm) 7 (177.8mm) 11⁄4 (31.7mm)

53⁄4 (146mm) 63⁄4 (171.4mm) 11⁄8 (28.6mm)

51⁄4 (133.3mm) 61⁄2 (165.1mm) 7⁄8 (22.2mm)

53⁄16 (131.8mm) 63⁄8 (161.9mm) 3⁄4 (19mm)

5 (127mm) 61⁄4 (158.8mm) 5⁄8 (15.9mm)

Page 41: Facts Figures Book

4141

KODIAK 200+Fine

Chamber

Mantle: 406052XBowl Liner: 406056X

Product Range: 3⁄8" to 3⁄4"Pinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl floatoccurs then you have gone beyond the allowable reduction ratio.)

KODIAK 200+Medium Chamberwith Feed Slots

Mantle: 406051XBowl Liner: 406054X

Product Range: 5⁄8" to 1"Pinion Speed: 900 RPMReduction Ratio: 4:1 to 6:1 Max. (Based on no bowl float. If bowl floatoccurs then you have gone beyond the allowable reduction ratio.)

All Dimensions in inchesA B C

71⁄2 (190.5mm) 81⁄2 (215.9mm) 11⁄4 (31.7mm)

71⁄4 (184.2mm) 81⁄4 (209.5mm) 11⁄8 (28.6mm)

7 (177.8mm) 8 (203.2mm) 7⁄8 (22.2mm)

67⁄8 (174.6mm) 77⁄8 (200mm) 3⁄4 (19mm)

63⁄4 (171.4mm) 73⁄4 (196.8mm) 5⁄8 (15.9mm)

All Dimensions in inchesA B C

31⁄8 (79.4mm) 6 (152.4mm) 7⁄8 (22.2mm)

3 (76.2mm) 41⁄2 (114.3mm) 5⁄8 (15.9mm)

27⁄8 (73mm) 41⁄2 (114.3mm) 1⁄2 (12.7mm)

23⁄4 (69.8mm) 41⁄2 (114.3mm) 3⁄8 (9.5mm)

Page 42: Facts Figures Book

42

NOTES:

Page 43: Facts Figures Book

43

KOD

IAK

300+

CON

ECR

USH

ERPR

OJE

CTED

CAPA

CITY

AND

GR

ADAT

ION

CHAR

TSProjected

OpenCircuitC

apacititesintons-per-hour

Clos

edSide

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"11⁄4"

11⁄2"

13⁄4"

2"Se

tting

(CSS

)12

.7mm

15.87mm

19.05mm

22.22mm

25.4

mm

32mm

38.1

mm

44.5

mm

50.8

mm

Gross

Throug

hput

170-21

019

0-24

021

5-27

024

0-30

027

0-33

031

0-38

533

0-41

535

0-44

037

0-46

0

Projected

ClosedCircuitC

apacititesintons-per-hour

Clos

edSide

3 ⁄8"

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"11⁄4"

Setting

(CSS

)9.52

mm

12.7

mm

15.87mm

19.05mm

22.22mm

25.4

mm

32mm

Recirc

ulating

Load

15%

15%

15%

17%

20%

21%

28%

Gross

Throug

hput

130-16

517

0-21

019

0-24

021

5-27

024

0-30

027

0-33

031

0-38

5

Net

Throug

hput

110-14

014

5-17

816

2-20

417

8-22

419

2-24

021

3-26

122

3-27

7

Minim

umclos

edside

setting

istheclos

etsetting

possible

that

does

notind

ucebo

wlfloat.

Actualminim

umclos

edside

setting

andprod

uctio

nnu

mbe

rswillvary

from

pittopita

ndareinflu

encedby

such

factorsas

nature

offeed

material,

ability

toscreen

outfines,m

anga

nese

cond

ition

,and

low

reliefs

ystem

pressu

re.

Page 44: Facts Figures Book

44

KODIAK 300+ CONE CRUSHERGRADATION CHART

Prod-uctSize

Crusher Closed Side Setting

5⁄16" 3⁄8" 7⁄16" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

7.94 9.52 11.11 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8mm mm mm mm mm mm mm mm mm mm mm mm

4" 100

31⁄2" 100 96

3" 100 95 90

23⁄4" 98 92 86

21⁄2" 100 95 88 81

21⁄4" 97 91 83 74

2" 100 94 86 76 65

13⁄4" 100 99 89 79 66 55

11⁄2" 100 99 97 82 68 56 45

11⁄4" 100 99 95 90 72 56 46 38

1" 100 99 95 87 79 60 45 36 29

7⁄8" 100 99 95 88 80 70 49 38 30 25

3⁄4" 100 97 95 91 83 71 61 41 32 26 21

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

Estimated product gradation percentages at setting shown.

Page 45: Facts Figures Book

45

KODIAK 300+MANGANESE

CONFIGURATION

KODIAK 300+Coarse Chamber

Mantle: 456262XBowl Liner: 456394X

KODIAK 300+Medium Coarse

Chamber

Mantle: 456262XBowl Liner: 45695X

Product Range: 3⁄4" to 11⁄2" Pinion Speed: 850 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

All Dimensions in inchesA B C

91⁄4 (234.9mm) 101⁄8 (257.1mm) 3⁄4 (19mm)

93⁄8 (238.1mm) 101⁄4 (260.3mm) 7⁄8 (22.2mm)

91⁄2 (241.3mm) 103⁄8 (263.5mm) 1 (25.4mm)

95⁄8 (244.4mm) 101⁄2 (266.7mm) 11⁄4 (31.7mm)

93⁄4 (274.6mm) 103⁄4 (273mm) 11⁄2 (38.1mm)

10 (254mm) 11 (279.4mm) 13⁄4 (44.4mm)

101⁄4 (260.3mm) 111⁄4 (285.8mm) 2 (50.8mm)

All Dimensions in inchesA B C

73⁄4 (196.8mm) 83⁄4 (222.2mm) 3⁄4 (19mm))

73⁄4 (196.8mm) 9 (228.6mm) 7⁄8 (22.2mm)

8 (203.2mm) 9 (228.6mm) 1 (25.4mm)

81⁄4 (209.5mm) 93⁄8 (238.1mm) 11⁄4 (31.7mm)

81⁄2 (215.9mm) 95⁄8 (244.4mm) 11⁄2 (38.1mm)

83⁄4 (222.2mm) 97⁄8 (250.8mm) 13⁄4 (44.4mm)

Product Range: 1" to 21⁄2" Pinion Speed: 850 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

Page 46: Facts Figures Book

46

KODIAK 300+MediumChamber

Mantle: 456262XBowl Liner: 456395X

Product Range: 3⁄4" to 13⁄4"Pinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

KODIAK 300+MediumChamber

withFeed Slots

Mantle: 456262XBowl Liner: 45696X

Product Range: 3⁄4" to 13⁄4"Pinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

All Dimensions in inchesA B C

77⁄8 (200mm) 87⁄8 (225.4mm) 5⁄8 (15.9mm)

8 (203.2mm) 9 (228.8mm) 3⁄4 (19mm)

81⁄8 (206.4mm) 91⁄8 (231.8mm) 7⁄8 (22.2mm)

81⁄4 (209.5mm) 91⁄4 (234.9mm) 1 (25.4mm)

81⁄2 (215.9mm) 91⁄2 (241.3mm) 11⁄4 (31.9mm)

All Dimensions in inchesA B C

61⁄2 (165.1mm) 75⁄8 (193.7mm) 5⁄8 (15.9mm)

65⁄8 (168.2mm) 73⁄4 (196.8mm) 3⁄4 (19mm)

63⁄4 (171.4mm) 77⁄8 (200mm) 7⁄8 (22.2mm)

67⁄8 (174.6mm) 8 (203.2mm) 1 (25.4mm)

71⁄8 (180.9mm) 81⁄4 (209.5mm) 11⁄4 (31.7mm)

Page 47: Facts Figures Book

47

KODIAK 300+Fine

Chamber

Product Range: 3⁄4" to 5⁄8"Pinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

KODIAK 300+Medium

Fine Chamber

Mantle: 456262XBowl Liner: 456397X

Product Range: 1⁄2" to 7⁄8"Pinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

All Dimensions in inchesA B C

35⁄8 (92mm) 51⁄8 (130.2mm) 1⁄2 (12.7mm)

33⁄4 (96.3mm) 51⁄4 (133.3mm) 5⁄8 (15.9mm)

37⁄8 (98.4mm) 53⁄8 (136.5mm) 3⁄4 (19mm)

4 (101.6mm) 51⁄2 (138.7mm) 7⁄8 (22.2mm)

41⁄8 (104.8mm) 55⁄8 (142.9mm) 1 (25.4mm)

All Dimensions in inchesA B C

23⁄4 (69.8mm) 43⁄8 (111.1mm) 1⁄4 (6.4mm)

27⁄8 (73mm) 41⁄2 (114.3mm) 3⁄8 (9.5mm)

3 (76.2mm) 45⁄8 (117.5mm) 1⁄2 (12.7mm)

31⁄8 (79.4mm) 43⁄4 (120.7mm) 5⁄8 (15.9mm)

31⁄4 (82.5mm) 47⁄8 (123.8mm) 3⁄4 (19mm)

33⁄8 (85.7mm) 5 (127mm) 7⁄8 (22.2mm)

Mantle: 456322XBowl Liner: 456398X

Page 48: Facts Figures Book

48

NOTES:

Page 49: Facts Figures Book

49

KOD

IAK

400+

CON

ECR

USH

ERPR

OJE

CTED

CAPA

CITY

AND

GR

ADAT

ION

CHAR

TSOpenCircuitC

apacititesintons-per-hour

Clos

edSide

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"11⁄4"

11⁄2"

13⁄4"

2"Se

tting

(CSS

)12

.7mm

15.87mm

19.05mm

22.22mm

25.4

mm

32mm

38.1

mm

44.5

mm

50.8

mm

Gross

Throug

hput

210-26

025

0-31

529

0-36

531

5-39

534

0-42

540

5-50

544

0-55

047

5-59

550

0-62

5

ClosedCircuitC

apacititesintons-per-hour

Clos

edSide

3 ⁄8"

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"11⁄4"

Setting

(CSS

)9.52

mm

12.7

mm

15.87mm

19.05mm

22.22mm

25.4

mm

32mm

Recirc

ulating

Load

15%

15%

15%

17%

20%

21%

28%

Gross

Throug

hput

165-20

021

0-26

025

0-31

529

0-36

531

5-39

534

0-42

540

5-50

5Net

Throug

hput

140-17

017

8-22

121

2-26

824

1-30

325

2-31

626

9-33

629

2-36

4

Minim

umclos

edside

setting

istheclos

etsetting

possible

that

does

notind

ucebo

wlfloat.

Actualminim

umclos

edside

setting

andprod

uctio

nnu

mbe

rswillvary

from

pittopita

ndareinflu

encedby

such

factorsas

nature

offeed

material,

ability

toscreen

outfines,m

anga

nese

cond

ition

,and

low

reliefs

ystem

pressu

re.

Page 50: Facts Figures Book

50

KODIAK 400+ CONE CRUSHERGRADATION CHART

Prod-uctSize

Crusher Closed Side Setting

5⁄16" 3⁄8" 7⁄16" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

7.94 9.52 11.11 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8mm mm mm mm mm mm mm mm mm mm mm mm

4" 100

31⁄2" 100 96

3" 100 95 90

23⁄4" 98 92 86

21⁄2" 100 95 88 81

21⁄4" 97 91 83 74

2" 100 94 86 76 65

13⁄4" 100 99 89 79 66 55

11⁄2" 100 99 97 82 68 56 45

11⁄4" 100 99 95 90 72 56 46 38

1" 100 99 95 87 79 60 45 36 29

7⁄8" 100 99 95 88 80 70 49 38 30 25

3⁄4" 100 97 95 91 83 71 61 41 32 26 21

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

Estimated product gradation percentages at setting shown.

Page 51: Facts Figures Book

51

KODIAK 400+MANGANESE

CONFIGURATION

KODIAK 400+Coarse

Chamber

Mantle: 546034XBowl Liner: 546745X

Product Range: 1" to 21⁄2"Pinion Speed: 850 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

KODIAK 400+MediumChamber

withFeed Slots

Mantle: 546034XBowl Liner: 546747X

Product Range: 3⁄4" to 11⁄4"Pinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

All Dimensions in inchesA B C

81⁄8 (206.3mm) 91⁄2 (241.3mm) 5⁄8 (15.9mm)

81⁄4 (209.5mm) 95⁄8 (244.4mm) 3⁄4 (19mm)

83⁄8 (212.7mm) 93⁄4 (274.6mm) 7⁄8 (22.2mm)

81⁄2 (215.9mm) 97⁄8 (250.8mm) 1 (25.4mm)

83⁄4 (222.2mm) 101⁄4 (260.3mm) 11⁄4 (31.7mm)

All Dimensions in inchesA B C

101⁄4 (260.3mm) 111⁄2 (292.1mm) 3⁄4 (19mm)

103⁄8 (263.5mm) 115⁄8 (295.3mm) 7⁄8 (22.2mm)

101⁄2 (266.7mm) 113⁄4 (298.4mm) 1 (25.4mm)

103⁄4 (273.1mm) 12 (304.8mm) 11⁄4 (31.7mm)

111⁄8 (282.6mm) 121⁄4 (311.2mm) 11⁄2 (38.1mm)

113⁄8 (288.9mm) 121⁄2 (317.5mm) 13⁄4 (44.4mm)

111⁄2 (292.1mm) 12 (323.8mm) 2 (50.8mm)

Page 52: Facts Figures Book

52

KODIAK 400+MediumChamber

Mantle: 546034XBowl Liner: 546746X

Product Range: 3⁄4" to 11⁄4"Pinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

KODIAK 400+Medium Fine

Chamber

Mantle: 546034XBowl Liner: 546748X

Product Range: 1⁄8 to 7⁄8"Pinion Speed: 900 to 950 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

All Dimensions in inchesA B C

65⁄8 (168.2mm) 81⁄8 (206.3mm) 5⁄8 (15.9mm)

63⁄4 (171.4mm) 81⁄4 (209.5mm) 3⁄4 (19mm)

67⁄8 (174.6mm) 83⁄8 (212.7mm) 7⁄8 (22.2mm)

7 (177.8mm) 81⁄2 (215.9mm) 1 (25.4mm)

73⁄8 (187.3mm) 83⁄4 (222.2mm) 11⁄4 (31.7mm)

All Dimensions in inchesA B C

31⁄2 (88.9mm) 51⁄4 (133.4mm) 1⁄2 (12.7mm)

33⁄4 (95.3mm) 53⁄8 (135.5mm) 5⁄8 (15.9mm)

37⁄8 (98.4mm) 51⁄2 (139.7mm) 3⁄4 (19mm)

4 (101.6mm) 53⁄4 (146mm) 7⁄8 (22.2mm)

41⁄8 (104.8mm) 57⁄8 (149.2mm) 1 (25.4mm)

Page 53: Facts Figures Book

53

KODIAK 400+Fine

Chamber

Mantle: 546038XBowl Liner: 546749X

Product Range: 1⁄4" to 5⁄8"Pinion Speed: 950 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occursthen you have gone beyond the allowable reduction ratio.)

All Dimensions in inchesA B C

21⁄8 (54mm) 37⁄8 (98.4mm) 1⁄4 (6.3mm)

21⁄4 (57.2mm) 4 (101.6mm) 3⁄8 (9.5mm)

23⁄8 (60.3mm) 41⁄8 (104.8mm) 1⁄2 (12.7mm)

21⁄2 (63.5mm) 41⁄4 (107.9mm) 5⁄8 (15.9mm)

25⁄8 (66.7mm) 43⁄8 (111.1mm) 3⁄4 (19mm)

Page 54: Facts Figures Book

54

NOTES:

Page 55: Facts Figures Book

55

1200

LS/1

400

LSCO

NE

CRU

SHER

PRO

JECT

EDCA

PACI

TYAN

DG

RAD

ATIO

NCH

ARTS

OpenCircuitC

apacititesintons-per-hour

Clos

edSide

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"11⁄4"

11⁄2"

13⁄4"

2"Se

tting

12.7

15.87

19.05

22.22

25.4

3238

.144

.550

.8(C

SS)

mm

mm

mm

mm

mm

mm

mm

mm

mm

Gross

1200

LS12

5-16

514

0-19

516

5-22

018

0-24

520

0-27

022

0-32

024

0-34

526

0-36

527

0-38

5Th

roug

hput

1400

LS17

0-21

520

0-25

522

5-28

523

0-30

524

0-35

026

5-39

029

5-40

531

5-45

033

0-48

0

ClosedCircuitC

apacititesintons-per-hour

Clos

edSide

1 ⁄4"

5 ⁄16"

3 ⁄8"

1 ⁄2"

5 ⁄8"

3 ⁄4"

7 ⁄8"

1"Se

tting

6.35

7.94

9.52

12.7

15.87

19.05

22.22

25.4

(CSS

)mm

mm

mm

mm

mm

mm

mm

mm

Recirc

ulating

Load

15%

15%

16%

20%

20%

20%

26%

28%

Gross

1200

LS75

-90

90-105

115-14

514

5-19

016

5-22

018

5-25

020

5-27

522

5-30

0Th

roug

hput

1400

LS11

5-14

514

5-19

019

0-23

522

5-28

024

0-31

524

5-33

526

5-37

5Net

1200

LS64

-77

77-90

97-122

116-15

213

2-17

614

8-20

015

2-20

416

2-21

6Th

roug

hput

1400

LS98

-123

122-16

015

2-18

818

0-22

419

2-25

218

1-24

819

1-27

0

Minim

umclos

edside

setting

istheclos

etsetting

possible

that

does

notind

ucebo

wlfloat.

Actualminim

umclos

edside

setting

andprod

uctio

nnu

mbe

rswillvary

from

pittopita

ndareinflu

encedby

such

factorsas

nature

offeed

material,

ability

toscreen

outfines,m

anga

nese

cond

ition

,and

low

reliefs

ystem

pressu

re.

Page 56: Facts Figures Book

56

1200 LS / 1400 LS CONE CRUSHERGRADATION CHART

Prod-uctSize

Crusher Closed Side Setting

5⁄16" 3⁄8" 7⁄16" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

7.94 9.52 11.11 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8mm mm mm mm mm mm mm mm mm mm mm mm

4" 100

31⁄2" 100 96

3" 100 95 90

23⁄4" 98 92 86

21⁄2" 100 95 88 81

21⁄4" 97 91 83 74

2" 100 94 86 76 65

13⁄4" 100 97 88 79 66 55

11⁄2" 100 96 91 80 68 56 45

11⁄4" 100 97 90 83 70 56 46 38

1" 100 99 90 82 72 58 45 36 29

7⁄8" 100 99 93 86 74 64 48 38 30 25

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

Estimated product gradation percentages at setting shown.

Page 57: Facts Figures Book

57

LS SERIES CRUSHER MANGANESECONFIGURATIONS

1200LSEnlarged

FeedCoarse

Chamber

Bowl Liner: 450127Mantle: 450263

A B C Max. Feed Material83⁄4 10 2 93⁄883⁄8 91⁄2 11⁄2 981⁄8 91⁄4 11⁄4 81⁄877⁄8 9 1 41⁄2

Product Range: 1" to 2" MinusPinion Speed: 750 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

1200LSCoarse

Chamber

Bowl Liner: 450127Mantle: 450128

A B C Max. Feed Material9 93⁄4 2 93⁄881⁄2 91⁄2 11⁄2 981⁄4 91⁄4 11⁄4 83⁄48 9 1 5

Product Range: 3⁄4" to 11⁄2" MinusPinion Speed: 750 to 850 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

All Dimensions in inches

All Dimensions in inches

Page 58: Facts Figures Book

58

1200LSMedium

FineChamber

Bowl Liner: 450177Mantle: 450128

A B C Max. Feed Material4 51⁄4 1 45⁄837⁄8 51⁄8 7⁄8 41⁄233⁄4 5 3⁄4 43⁄831⁄2 43⁄4 1⁄2 4

Product Range: 1⁄2" to 1⁄2" MinusPinion Speed: 800 to 900 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

All Dimensions in inches

Page 59: Facts Figures Book

59

CRU

SHER

MO

TOR

SHEA

VESH

EAVE

LIN

ERS

PINI

ONSP

EED

SHEA

VEH

UB

BOR

ESH

EAVE

HU

B

COAR

SE75

0RPM

6-8V

-24.8

M21

5 ⁄16

6-8V

-16.0

JMED

IUM

800RPM

6-8V

-24.8

M21

5 ⁄16

6-8V

-17.0

J

MED

/FIN

E85

0RPM

6-8V

-24.8

M21

5 ⁄16

6-8V

-18.0

JFINE

EX/FIN

E90

0RPM

6-8V

-24.8

M21

5 ⁄16

6-8V

-19.0

J

KPI-

JCI1

200L

SV-

BELT

DR

IVE

DAT

A–

SIN

GLE

MO

TOR

1200

RPM

MO

TOR

–20

0H

PSI

NG

LE

1800

RPM

MO

TOR

–20

0H

PSI

NG

LE

CRU

SHER

MO

TOR

SHEA

VESH

EAVE

LIN

ERS

PINI

ONSP

EED

SHEA

VEH

UB

BOR

ESH

EAVE

HU

B

COAR

SE72

5RPM

8-8V

-30

N8-8V

-12.5

JMED

IUM

775RPM

8-8V

-30

N8-8V

-13.2

J

MED

/FIN

E82

5RPM

8-8V

-30

N8-8V

-14.0

JFINE

EX/FIN

E87

5RPM

8-8V

-24.8

N8-8V

-12.5

J

Page 60: Facts Figures Book

60

1400LSCoarse

Chamber

Bowl Liner: 540113Mantle: 540101

A B C Max. Feed Material111⁄4 12 2 115⁄8103⁄4 111⁄4 11⁄2 11101⁄2 11 11⁄4 8101⁄4 103⁄4 1 6

Product Range: 1" to 21⁄2" MinusPinion Speed: 700 to 800 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

1400LSMediumChamber

Bowl Liner: 540115Mantle: 540101

A B C Max. Feed Material83⁄4 91⁄2 11⁄4 91⁄881⁄2 91⁄4 1 87⁄883⁄8 91⁄8 7⁄8 881⁄4 9 3⁄4 4

Product Range: 5⁄8" to 1" MinusPinion Speed: 700 to 850 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

All Dimensions in inches

All Dimensions in inches

Page 61: Facts Figures Book

61

1400LSMedium

FineChamber

Bowl Liner: 540114Mantle: 540101

A B C Max. Feed Material4 51⁄2 1 43⁄433⁄4 51⁄4 7⁄8 41⁄235⁄8 51⁄8 3⁄4 43⁄831⁄2 5 5⁄8 41⁄4

Product Range: 3⁄8" to 3⁄4" MinusPinion Speed: 750 to 850 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

1400LSFine

Chamber

Bowl Liner: 540274Mantle: 540273

A B C Max. Feed Material21⁄2 41⁄8 3⁄4 31⁄423⁄8 4 5⁄8 31⁄821⁄4 37⁄8 1⁄2 311⁄8 33⁄4 3⁄8 3

Product Range: 3⁄8" to 5⁄8" MinusPinion Speed: 800 to 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

All Dimensions in inches

All Dimensions in inches

Page 62: Facts Figures Book

62

CRU

SHER

MO

TOR

SHEA

VESH

EAVE

LIN

ERS

PINI

ONSP

EED

SHEA

VEH

UB

BOR

ESH

EAVE

HU

B

COAR

SE75

0RPM

10-8V-24

.8N

31⁄2

10-8V-16

.0M

MED

IUM

800RPM

10-8V-24

.8N

31⁄2

10-8V-17

.0M

MED

/FIN

E85

0RPM

10-8V-24

.8N

31⁄2

10-8V-18

.0M

FINE

900RPM

10-8V-24

.8N

31⁄2

10-8V-19

.0M

X/FINE

950RPM

10-8V-24

.8N

31⁄2

10-8V-20

.0M

1400

LSV-

BELT

DR

IVE

DAT

A–

SIN

GLE

MO

TOR

1200

RPM

MO

TOR

–30

0H

PSI

NG

LE

1800

RPM

MO

TOR

–30

0H

PSI

NG

LE

CRU

SHER

MO

TOR

SHEA

VESH

EAVE

LIN

ERS

PINI

ONSP

EED

SHEA

VEH

UB

BOR

ESH

EAVE

HU

B

COAR

SE72

5RPM

12-8V-30

.0P

12-8V-12

.5M

MED

IUM

775RPM

12-8V-30

.0P

12-8V-13

.2M

MED

/FIN

E82

5RPM

12-8V-30

.0P

12-8V-14

.0M

FINE

EX/FIN

E87

5RPM

12-8V-24

.8N

12-8V-12

.5M

Page 63: Facts Figures Book

63

ROLL CRUSHERSAPPROXIMATE TWIN AND TRIPLE ROLLCRUSHER GRADATION—OPEN CIRCUIT

TestSieveSizes(in.)

TestSieveSizes(mm)

Roll Crusher Settings

1⁄4" 3⁄8" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 4"

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

8" 203

6" 152

5" 127

4" 85 102

3" 85 63 75.2

21⁄2" 85 70 50 63.5

2" 85 69 54 36 50.8

11⁄2" 85 62 50 37 26 38.1

11⁄4" 85 70 50 40 31 22 31.8

1" 85 70 52 38 31 25 17 25.4

3⁄4" 85 65 50 36 27 24 19 14 19.0

1⁄2" 85 60 40 29 24 20 16 14 10 12.7

3⁄8" 85 65 40 27 22 19 15 13 11 8 9.53

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 increasingfeed and corresponding horsepower.

Values Shown are

Percent Passing

Page 64: Facts Figures Book

64

ROLL CRUSHERS APPROXIMATE TWINAND TRIPLE ROLL CRUSHER GRADATION—

CLOSED CIRCUIT WITH SCREEN

TestSieveSizes(in.)

TestSieveSizes(mm)

Roll Crusher Settings

1⁄4" 3⁄8" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 4"

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

4" 100 102

3" 100 79 76.2

21⁄2" 100 91 64 63.5

2" 100 85 75 48 50.8

11⁄2" 100 79 63 55 35 38.1

11⁄4" 100 90 63 50 44 29 31.8

1" 100 85 75 46 39 34 23 25.4

3⁄4" 100 80 66 55 33 28 25 18 19.0

1⁄2" 100 75 55 41 33 22 20 18 13 12.7

3⁄8" 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

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

Values Shown are

Percent Passing

Roll Setting 80% of

Screen Mesh Size

Page 65: Facts Figures Book

65

TWIN ROLL CRUSHERSRECOMMENDED HP

Size Electric Diesel (Continuous)

2416 50 753018 100 1503024 125 1753030 200 3004022 150 2004030 250 3254240 300 4005424 250 3255536 350 475

APPROXIMATE CAPACITIES IN TPH FOR OPEN CIRCUIT(Use 85 percent of these values in closed circuit)

Roll Settings

Size 1⁄4" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3"

2416 16 31 47 63 79 943018 25 50 75 100 125 150 2003024 33 66 100 133 166 200 2663030 41 82 125 166 207 276 344 4144022 34 69 103 138 172 207 276 344 4144030 53 106 160 213 266 320 426 532 6404240 70 141 213 284 354 426 568 709 8535424 44 87 131 175 228 262 350 437 5255536 65 130 195 261 326 390 522 652 782

*With smooth shells �� No beads �� Bead one shell �� Bead two shells** Not current production models

*Based on 50% of theoretical ribbon of material of 100# / Ft.3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find Yd.3 /Hr. multiply by .74.For larger settings—consult Factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES)Roll 24" Dia. 30" Dia. 40" or 42" 54" or 55"

Setting Rolls Rolls Dia. Rolls Dia. Rolls1⁄4 1⁄2 1⁄2 5⁄8 3⁄43⁄8 3⁄4 3⁄4 1 11⁄81⁄2 1 1 11⁄4 11⁄23⁄4 11⁄2 11⁄2 17⁄8 21⁄41 2 2 21⁄2 3

11⁄4 23⁄8 23⁄8 27⁄8 33⁄811⁄2 23⁄4 23⁄4 31⁄8 33⁄42 31⁄2 33⁄4 41⁄2

21⁄2 43⁄8 51⁄43 5 6

****

****

****

****

****

****

Page 66: Facts Figures Book

66

TWIN ROLL CRUSHERSRECOMMENDED HP

Size Electric Diesel (Continuous)

2416 50 753018 100 1503024 125 1753030 200 3004022 150 2004030 250 3254240 300 4005424 250 3255536 350 475

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 76.2Size mm mm mm mm mm mm mm mm mm2416 14 28 43 57 72 853018 23 45 68 91 113 136 1813024 30 60 91 121 150 181 2413030 37 74 113 150 188 227 3014022 31 62 93 125 156 188 250 312 3754030 48 96 145 193 241 290 386 483 5804240 64 128 193 257 321 386 514 644 7735424 40 79 119 159 207 238 317 396 4765536 59 118 177 237 296 354 473 591 709*Based on 50% of theoretical ribbon of material of 1600 kg/m3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find cubic meters per hour, multiply by 1.6.For larger settings—consult Factory.MAXIMUM FEED SIZE VS. ROLL SETTING* (MILLIMETERS)

1016 mm or 1372 mm orRoll 610 mm 762 mm 1066 mm 1397 mm

Setting Dia. Rolls Dia.Rolls Dia. Rolls Dia. Rolls6.35 12.7 12.7 15.9 19.09.52 19.0 19.0 25.4 28.812.7 25.4 25.4 31.7 38.119.0 38.1 38.1 47.6 57.125.4 50.8 50.8 63.5 76.231.7 60.3 60.3 73.0 85.738.1 69.8 69.8 79.4 95.250.8 88.9 95.2 11463.5 111 13376.2 127 152

****

****

****

****

****

****

Page 67: Facts Figures Book

67

TRIPLE ROLL CRUSHERSRECOMMENDED HP

Size Electric Diesel (Continuous)

3018 125 1753024 150 2003030 250 3754022 200 2754030 300 4004240 400 5255424 300 4005536 450 600

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" 11⁄4" 11⁄2" 2" 21⁄2"

3018 37 75 112 150 187 2253024 52 104 156 208 260 3123030 65 130 195 260 325 3904022 58 117 176 234 292 350 468 5844030 79 159 238 318 398 476 636 7964240 105 212 317 424 530 634 848 10615424 65 131 198 262 328 392 524 6555536 97 195 293 391 489 586 782 977*Based on 75% of theoretical ribbon of material of 100# / Ft.3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find Yd.3 / Hr. multiply by .74.For larger settings—consult Factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES)30" Dia. 40" or 42" 54" or 55"Rolls Dia. Rolls Dia. Rolls

Smaller Larger Max. Larger Max. Larger MaxSetting Setting Feed Setting Feed Setting Feed

1⁄4 1⁄2 1 9⁄15 11⁄4 5⁄8 11⁄23⁄8 3⁄4 11⁄2 13⁄16 17⁄8 15⁄16 21⁄41⁄2 1 2 11⁄8 17⁄8 15⁄16 21⁄43⁄4 11⁄2 3 111⁄16 33⁄4 113⁄16 41⁄21 17⁄8 31⁄2 21⁄4 5 27⁄16 611⁄4 2 31⁄2 21⁄2 5 27⁄16 611⁄2 2 31⁄2 23⁄4 5 3 62 3 5 3 621⁄2 3 5 3 6

*With smooth shells �� No beads �� Bead one shell �� Bead two shells** Not current production models

**

****

****

**

****

****

Page 68: Facts Figures Book

68

TRIPLE ROLL CRUSHERSRECOMMENDED HP

Size Electric Diesel (Continuous)

3018 125 1753024 150 2003030 250 3754022 200 2754030 300 4004240 400 5255424 300 4005536 450 600

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 6.35 12.7 19.0 25.4 31.7 38.1 50.8 63.5

3018 33 68 102 136 170 2043024 47 94 141 189 236 2833030 59 118 177 236 295 3544022 53 106 160 212 265 317 424 5304030 72 144 216 288 361 432 577 7224240 96 192 288 384 481 576 769 9625424 59 119 180 238 297 356 475 5945536 88 177 266 355 444 532 709 886

*Based on 75% of theoretical ribbon of material of 1600 kg/m3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find cu. meters per hour, multiply by 1.6.For larger settings—consult Factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (MM)762 mm Dia. 1016 mm or 1066 mm 1372 mm or 1397 mm

Rolls Dia. Rolls Dia. RollsSmaller Larger Max. Larger Max. Larger MaxSetting Setting Feed Setting Feed Setting Feed6.35 12.7 25.4 14.3 31.7 15.9 38.19.52 19.0 38.1 20.6 47.6 23.8 57.112.7 25.4 50.8 28.6 63.5 31.7 76.219.0 38.1 76.2 42.9 95.2 46.0 11425.4 47.6 88.9 57.1 127 61.9 15231.7 50.8 88.9 63.5 127 69.8 15238.1 50.8 88.9 69.8 127 76.2 15250.8 76.2 127 76.2 15263.5 76.2 127 76.2 152

**

****

****

**

****

****

*With smooth shells �� No beads �� Bead one shell �� Bead two shells** Not current production models

Page 69: Facts Figures Book

69

CAPACITY MULTIPLIERS FOR OPEN CIRCUITTWIN FEED VS. SINGLE FEED

TRIPLE ROLLSTriple roll twin feed capacities are obtained by selecting a multiplierfrom the chart (depending on coarse/fine feed ratio) and applying thesame to the single feed triple roll capacity. Roll crusher capacities atgiven settings will vary depending on horsepower available, slippageof 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 Capacity Through Capacity That isCoarse/Fine Crusher Product Size

20/80 .83 .7330/70 .97 .7740/60 1.13 .8550/50 1.35 .9560/40 1.66 1.1267/33 2.00 1.3070/30 1.95 1.2480/20 1.75 1.0490/10 1.55 .82

EXAMPLE: (4030 Triple Roll)

(1) Single feed capacity for 1⁄2"—(12.7 mm—) Product = 159 TPH(144 t/h).

(2) Twin feed capacity with “feed split ratio coarse/fine” 67/33 is159 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).

(12.7 mm)

(25.4 mm)1"

1⁄2"

Page 70: Facts Figures Book

70

Rubber Star Gears No. ofCounter- Tires Working Springsshaft Shell Working Centers, Per

Unit Pinion Gear RPM FPM Centers, In. Inches Roll

2416 15 68 270 346 — 221⁄4-253⁄4 23018 17 82 325 530 — 281⁄4-33 23024 17 82 325 530 30-32 281⁄4-33 2

(7 x 18)3030 19 73 300 623 30-32 — 8

(7 x 18)4022 18 103 325 600 39-42 371⁄2-421⁄2 8

(10 x 22)40-43

(11 x 22)4030 19 91 310 680 39-42 371⁄2-421⁄2 8

(10 x 22)40-43

(11 x 22)4240 17 88 320 680 41-45 — 85424 19 118 310 700 53-58 53-57 8

(12 x 36) 88

5536 17 88 250 700 53-58 — 12(12 x 36)

No. ofTeeth

DETAIL DATA FOR ROLL CRUSHERPERFORMANCE (TWIN ROLLS)

Rubber Star Gears No. ofCounter- Tires Working Springsshaft Shell Working Centers, Per

Unit Pinion Gear RPM FPM Centers, In. Inches Roll3018 17 82 325 530 — 281⁄4-33 2

22

3024 18 82 325 555 30-32 281⁄4-33 2( 7 x 18)

3030 19 73 300 623 30-32 — 8( 7 x 18)

4022 19 91 310 680 39-42 371⁄2-421⁄2 8(10 x 22)40-43 8

(11 x 22)8

4030 19 91 310 680 39-42 371⁄2-421⁄2 8(10 x 22)40-43 8

(11 x 22)4240 17 88 320 680 41-45 — 125424 19 118 310 700 53-58 53-57 8

(12 x 36) 888

5536 17 88 250 700 53-58 — 12(12 x 36)

No. ofTeeth

DETAIL DATA FOR ROLL CRUSHERPERFORMANCE (TRIPLE ROLLS)

** Not current production models

****

**

**

**

**

**

**

**

**

**

Page 71: Facts Figures Book

71

VERTICAL SHAFT IMPACT

Rubber tire mounted

Stationary Plant

Bare unit

Page 72: Facts Figures Book

72

These Vertical Shaft Impact Crushers are best appliedin tertiary and quaternary applications and various sec-ondary applications. Rock fed to the crusher’saccelerator mechanism (table or rotor) is flung out-wards by centrifugal force against the stationary anvilsor hybrid rock shelf for free-body impacting. Theproper chamber configuration is application depen-dent.

Major crushing advantages include: precise gra-dation control; production of chips and asphaltaggregates fines; compliance with cubical andfracture count specifications, for todays tightspecification requirements such as Superpave.

VERTICAL SHAFTIMPACT CRUSHER OPERATION

Page 73: Facts Figures Book

73

VERT

ICAL

SH

AFT

IMPA

CT C

RU

SHER—Specifications and Production Characteristics

Mod

elInch

MM

Mesh

Inch

TPH

MTP

HRPM

H.P.

Inch

MM

Cubic Inch

Lbs-Ft

Lbs

Kgs

1500

(H)

250

#16

81⁄2

75-125

67-112

720-20

0075

-150

10.4

260

4,63

51,10

013

,200

6,00

0

1500

(A)

250

#481⁄2

75-150

67-135

720-20

0015

0—

—4,63

51,10

013

,700

6,00

0

2500

(H)

375

#16

113 ⁄ 8

150-25

013

5-22

370

0-14

0025

08.8

220

10,120

2,40

018

,000

8,18

2

2500

(A)

250

#411

3 ⁄ 815

0-30

013

5-26

770

0-14

0030

0—

—10

,120

2,40

019

,000

8,18

2

823

75#1

614

.025

0-40

022

7-35

680

0-12

0040

0-50

08.7

218

10,940

3,20

024

,000

11,000

4500

(H)

375

4M16

.030

0-45

026

7-40

180

0-12

0040

0-50

010

.25

(256

)17

,360

3,83

029

,600

13,320

4500

(H)

512

53 ⁄8"

16.0

300-45

026

7-40

180

0-12

0040

0-50

011

.75

294

17,360

3,83

029

,600

13,320

4500

(A)

21⁄ 2

63#4

16.0

300-50

026

7-44

580

0-12

0040

0-50

0—

—17

,360

3,50

029

,100

13,320

120

615

03 ⁄8"

18.0

300-50

026

7-44

580

0-10

8040

0-60

014

.75

369

26,020

5,60

032

,100

14,595

Minim

umStan

dard

Approx

imate

Recom

men

ded

Capa

city

Impe

ller

Recom

men

ded

Explos

ion

Weigh

tMaxim

umClos

edFeed

Tub

eEffective Cr

ushing

Table Sp

eed

Electric

Table/An

vil

Cham

ber

EV-M

odels

(Electric

Feed

Size (1)

Circuit

Diameter

Ran

ge (2

)Ran

geHorsepo

wer

Clearanc

eVo

lume

WK2

Show

n)

NO

TE:

(H) in the mod

el num

ber d

enotes hardp

arts con

figuration also

referred

to as “stand

ard co

nfiguration.”

(A) in the mod

el num

ber d

enotes autog

enou

s co

nfiguration. The

spe

cific

ation an

d prod

uctio

n rates sh

own ap

ply to sem

i and

fully autog

enou

s.(1) M

ax fe

ed size restric

tion can vary w

ith re

gards to m

aterial d

ensity, c

rush

ability, e

long

ation, and

impe

ller tab

le spe

ed or c

onfig

uration.

(2) F

eed size and

throug

hput to

nnag

e ba

sed on

material w

eigh

ing 10

0 lbs. per cub

ic fo

ot.

Page 74: Facts Figures Book

74

Secondary

80%

of M

ax.

50%

of M

ax.

Max

. Spe

edSp

eed

Out

put

Spee

d O

utpu

tSi

eve

Size

Siev

e Si

zeFe

ed S

calp

edin

ches

mm

at 1

1 ⁄2" (1

)%

Pas

sing

6"15

2mm

5"12

5mm

100%

4"10

0mm

100%

993"

75mm

100%

9997

2"50

mm

9691

8611⁄2"

37.5mm

9081

7011⁄4"

31.5mm

8677

631"

25.0mm

7868

527 ⁄8"

22.4mm

7464

483 ⁄4"

19.0mm

6856

405 ⁄8"

16.0mm

6251

361 ⁄2"

12.5mm

5342

303 ⁄8"

9.5m

m44

3424

1 ⁄4"

6.3m

m35

2719

#4M

4.75

mm

2924

16#8

M2.36

mm

1715

11#1

6M1.18

mm

1413

8#3

0M60

0um

109

6#5

0M30

0um

76

4#1

00M

150u

M5

43

#200

M75

uM3

22

AVER

AGE

MAT

ERIA

LS C

RU

SHER

OU

TPU

T,(2

) USI

NG

3-S

HO

E/4-

SHO

E IM

PELL

ER

SECONDARY CRUSHING AVERAGE MATERIALS

(BASALT, HARD LIMESTONE, GRAVEL/DOLOMITE)

W/STANDARD CONFIGURATION

NO

TE:

(1) Feed

s sh

own are typical feed grad

ations

whe

n follo

wing a prim

ary jaw

set a

t 3" to 4" or a prim

ary im

pactor set at 2

" to 3" w

ith produ

ct sized

material rem

oved

.

(2) C

rush

er outpu

ts sho

w average

value

s ba

sed on

field expe

rienc

e, and

are

taken be

fore screening

produ

ct sized

material o

ut. T

he figu

res are pro-

vide

d for es

timating

requ

ired

screen

areas

and

tertia

ry crush

ing

equipm

ent w

hen us

ed w

ith th

e expe

cted

tonn

age of crush

er th

roug

h-pu

t. Va

lues w

ill differ w

ith each sp

ecific crus

hing

app

lication, so these

figures are not gua

rantees. Factors th

at can

affe

ct outpu

t grada

tion are:

feed

grada

tion, feed tonn

age, feed friability, im

peller table co

nfigura-

tion, im

pelle

r sp

eed, m

oisture co

nten

t, clos

ed circ

uit sc

reen

cloth

open

ing, available screen

area an

d ho

rsep

ower.

Model 4500

Model 120

Max Feed Size Range “Cubed”

4-5" (100-125 mm)

5-6" (125-150 mm)

Crusher Throughput

300-450 TPH

300-500 TPH

Page 75: Facts Figures Book

75

Typical Limestone in

Standard Configuration

PRODUCING A COARSE GRADED MATERIAL,

EMPHASIS ON CHIPS, POPCORN, AND

DIMENSIONAL PRODUCTS

Maximum

Crusher

Feed Size:

Throughput

“Cubed”

Capacity

Model 1500H

2" (50mm)

75-125 TPH

Model 2500H

3" (75mm)

150-250 TPH

Model 82H

3" (75mm)

250-400 TPH

Typical coarse gradations require 50%

-80%

maximum speed, 3 or

4 shoe table. Typically dense gradations require 70% - 100%

maximum speed, 4 or 5 shoe table.

Tertiary

Siev

e Si

zeSi

eve

Size

Typi

cal

Typi

cal

Typi

cal

inch

esm

mFe

edO

utpu

tFe

edO

utpu

tFe

edO

utpu

t3"

75mm

100%

2"50mm

98100%

11⁄2"

37.5mm

9498

1"25mm

8390

100%

3 ⁄4"

19mm

6978

951 ⁄ 2"

12.5mm

5260

803 ⁄8"

9.5mm

4046

621 ⁄ 4"

6.3mm

2833

40#4M

4.75mm

2024

30#8M

2mm

1415

15#16M

1.18mm

910

10#30M

600uM

67

7#50M

300uM

45

5#100M

150uM

34

4#200M

75uM

23

3

Models 1500H, 2500H, 82H

3" Feed

2" Feed

1" Feed

Page 76: Facts Figures Book

76

Typical Limestone in

Standard Configuration

PRODUCING A DENSE GRADED MATERIAL,

EMPHASIS ON FINES FOR BASE, ASPHALT

MATERIAL, SAND SUPPLEMENT, ETC.

Feeds:Typical feeds shown have been screened to take out prod-

uct sized material, and are initial feed plus recirculating load.

Outputs:These outputs show average values based on field expe-

rience crushing tough material, and indicate crusher output before

screening product sized material out. Gradation change is due to

increased impeller speed from 50% to 100% of maximum and a dif-

ference in impeller table configuration. Values will differ for each

specific crushing application. Factors that can affect output grada-

tion are: feed gradation, feed tonnage, feed friability, impeller table

configuration, impeller speed, moisture content, closed circuit

screen cloth opening, available screen area and horsepower.

Tertiary

Siev

e Si

zeSi

eve

Size

Typi

cal

Typi

cal

Typi

cal

inch

esm

mFe

edO

utpu

tFe

edO

utpu

tFe

edO

utpu

t3"

75mm

100%

2"50mm

9811⁄2"

37.5mm

95100%

1"25mm

8794

100%

3 ⁄4"

19mm

7985

991 ⁄ 2"

12.5mm

6873

903 ⁄8"

9.5mm

5762

781 ⁄ 4"

6.3mm

4649

63#4M

4.75mm

3740

52#8M

2mm

2627

33#16M

1.18mm

1718

21#30M

600uM

1112

15#50M

300uM

78

10#100M

150uM

56

6#200M

75uM

44

4

Models 1500H, 2500H, 82H

3" Feed

2" Feed

1" Feed

Page 77: Facts Figures Book

77

Typical Limestone in

Standard Configuration

1" FEED SIZE APPLICATIONS

Models 1500H, 2500H, 82H

Crushing 1" top feed size for chips, popcorn, fracture count, or a

manufactured sweetener.

Low Range

Resulting from:

•tough feed material

•impeller speeds 50-80% of max.

•crusher choke-fed

•3 or 4 shoe table

High Range

Resulting from:

•moderately tough to moderately friable feed material

•impeller speeds 80-100%

of max

•crusher fed 85% of choke-feed rate, or less

•five shoe table

*Shows high range with the effect of normal field screening ineffi-

ciencies. A proportional return of the coarse screen through

fractions and hydraulic classification to remove a portion of the

#100 mesh minus is usually required to meet ASTM C-33 specifi-

cations regarding a #4M minus gradation.

Quaternary

High Range

Low

High

Screened

Feed

Range

Range

Average

at #4M

*Sieve Size Sieve Size

inches

mm

% Passing

1"25mm

100%

100%

100%

3 ⁄4"

19mm

9599

971 ⁄2"

12.5mm

8090

853 ⁄8"

9.5mm

6278

701 ⁄4"

6.3mm

4063

52#4

4.75mm

3052

41100%

#82.36mm

1533

2475

#16

1.18mm

1021

1548

#30

600uM

615

1134

#50

300uM

510

722

#100

150uM

46

513

#200

75uM

34

39

Approx. Crusher Output

Models 1500H, 2500H, 82H

Page 78: Facts Figures Book

78

Autogenous

Sieve Size

Sieve Size

11⁄2"

100%

100%

inches

mm

Feed

Speed

Speed

2"50mm

11⁄2"

37.5mm

100%

11⁄4"

31mm

99100%

1"25mm

9596

3 ⁄4"

19mm

9090

1 ⁄2"

12.5mm

7076

3 ⁄8"

9.5mm

5658

1 ⁄4"

6.3mm

3845

#4M

4.75mm

3137

#8M

2mm

2225

#16M

1.18mm

1517

#30M

600uM

1113

#50M

300uM

88

#100M

150uM

65

#200M

75uM

43

Fully

Autogenous

Sem

i-Autogenous

Typical Sand and Gravel in

Autogenous and Sem

i Autogenous

Configuration

Maximum

Crusher

Feed Size:

Throughput

“Cubed”

Capacity

Model 1500A

2"75-150 TPH

Model 2500A

2"150-300 TPH

Model 4500A

21⁄2"

300-500 TPH

Based upon material weighing 2,700 lbs.. per cubic yard (1600

kg/m

3 ). Capacities may vary as much as ±25% dependent upon

methods of loading, characteristics and gradation of material, con-

dition of equipment and other factors.

Models 1500A, 2500A, 4500A

Page 79: Facts Figures Book

79

VERTICAL SHAFT IMPACT CRUSHER CRUSHING CHAMBER TERMINOLOGY

ROTOR & HYBRIDROCK SHELFRock-on-rock crushing;rotor flings rock againstbed of rock on outerhybrid rock shelf, andexposed portion of anvilslining the hybrid rock shelffor free-body impacting.Variable reduction ratiosof 10:1 to 3:1.

FULLY AUTOGENOUS

ROTOR & ANVILCrushing chamber hasautogenous rotor andstandard stationary anvilsfor specialized crushingand materials problems;11⁄2-2" feed sizes and vari-able reduction ratios of10:1 to 3:1.

SEMI-AUTOGENOUS

SHOE & ANVILImpeller shoes in cham-ber fling rock at true rightangles to stationaryanvils; rock gradationscontrolled by impellertable speed. Variablereduction ratios of 10:1 to3:1.

STANDARD CONFIGURATION

Page 80: Facts Figures Book

80

Purpose: Fast Trax® HSI Plants may be used to crush alltypes of aggregate, recycle concrete and asphalt inapplications where high mobility and/or small operating areasare required. These machines are used as primary crushers,secondary crushers, or total process solutions to reducematerial size for crusher run products, secondary processing,decrease overall volume, or to make finished sized productswhen the on-board close circuit screen is utilized.

Design: The self contained and self powered Fast Trax® HSIOpen Circuit Crushing Plants include a vibrating grizzly feeder(VGF), bypass chute, Andreas HSI, end delivery conveyor anddust suppression nozzles and plumbing. In addition, the closecircuit plants include a screen with closed circuit and underscreen conveyors. Independently driven and controlled tracksare used to maneuver the plant in the pit, as well as on to andoff of a flat bed transport. Options include; side deliveryconveyor for grizzly throughs and magnet for ferrouscontamination removal, a bag house air intake system, dustsuppression nozzles, and plumbing. Important standardfeatures include remote control of: tracks forward / reverse,engine speed idle / run, crusher on / off, feeder on / off andvariable speed, as well as, all of the features of the industryleading Andreas HSI Crushers and Feeders.

Application: Fast Trax® HSI Plants are typically used for topsizing materials or making finished sized product(s) andoptionally making one “free run” product from the grizzlybypass material. Plant capacity depends on the feed gradationHSI crusher settings and screen cloth opening (if equipped).Reference the HSI and screen section of this handbook formore details. For operating parameters outside theseguidelines contact.

FAST TRAX® HORIZONTAL SHAFTIMPACTOR (HSI) PLANTS

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81

Purpose: Fast Trax® Jaw Plants are used to crush all types ofaggregate, recycle concrete, and asphalt in applicationswhere high mobility and/or small operating areas are required.These machines are used as primary crushers to reducematerial size for crusher run products, secondary processing,or to decrease overall volume.

Design: The self contained and self powered Fast Trax® JawCrushing Plants include a vibrating grizzly feeder (VGF),bypass chute, Vanguard Jaw Crusher, and end deliveryconveyor. Independently driven and controlled tracks are usedto maneuver the plant in the pit, as well as, on to and off of aflat bed transport. Options include; side delivery conveyor forgrizzly throughs, magnet for ferrous contamination removal, abag house air intake system, dust suppression nozzles andplumbing. Important standard features include remote controlof: tracks forward / reverse, engine speed idle / run, crusheron / off, feeder on / off and variable speed as well as all of thefeatures of the industry leading Vanguard Jaw Crushers andFeeders.

Application: Fast Trax® Jaw Plants are typically used asprimary crushers for top sizing materials and optionally makingone “free run” product from the grizzly bypass material. Plantcapacity depends on the feed gradation and jaw crusherclose-side-setting. Reference the jaw crusher section of thishandbook for more details. For operating parameters outsidethese guidelines contact.

FAST TRAX® JAW PLANTS

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82

Purpose: Fast Trax® Cone Plants are used to crush all typesof aggregate and recycle concrete in applications where highmobility and/or small operating areas are required. Thesemachines are used as secondary or final sizing crushers toreduce material size for producing specification products suchas specified base, asphalt, and concrete aggregates, etc.

Design: The self contained and self powered Fast Trax® ConeCrushing Plants include a feed conveyor with a hydraulic headsection that can be raised to allow access to the crusher formanganese changes, a Kodiak® Cone Crusher with crusherhopper, and an end delivery conveyor. The feed conveyor canbe configured in (3) different positions (RH, LH, or Center) andthe end delivery conveyor can be positioned to discharge outeither end of the plant to facilitate multiple systemconfiguration options. Independently driven and controlledtracks are used to maneuver the plant in the pit, as well as, onto and off of a flat bed transport. Options include a bag houseair intake system, dust suppression nozzles, and plumbing.At the heart of the machine is the industry-leading Kodiak®

Cone Crusher, which is an established industry leader withtraditional aggregate producers.

Application: Fast Trax® Cone Plants are typically used assecondary or tertiary crushers for sizing finished products,providing an additional reduction machine, or providing anadditional machine to improve particle shaping. Plant capacitydepends on the feed characteristics and cone crusher close-side-setting. The maximum feed size is dependant on the linerconfiguration (refer to “Kodiak® Cone Crusher” section), or justbelow the point at which bowl float occurs. The minimumclose-side-setting of the cone is a maximum of 8:1 reductionratio relative to the maximum feed size, or just above the pointat which bowl float occurs. For operating parameters outsidethese guidelines contac.

FAST TRAX® CONE PLANTS

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83

Purpose: Fast Trax® Screen Plants are used to separate all typesof bulk materials including aggregates, recycle materials, andother applications where high mobility and/or small operatingareas are required. These machines are used for both light dutyscalping, fines removal, and finishing screening operations. Thesescreen plants are available with both incline and horizontalscreens in both open and closed-circuit configurations.

Design: The self contained and self powered Fast Trax® ScreenPlants include either a pan or roller belt variable speed feeder, aVibrating Screen in either a single shaft incline or triple shafthorizontal design, side discharge conveyors for finished products,and an end delivery conveyor for oversized material. The FT5162features interchangeable top deck media configurations (punchplate, wire, finger decks). The FT6203CC configuration featuresan articulating end delivery conveyor and overhead feed conveyorto facilitate closed-circuit operation with a Fast Trax® cone or H.S.I.plants for multiple system configuration options with minimaltransition points. Independently driven and controlled tracks areused to maneuver the plant in the pit, as well as, on to and off ofa flat bed transport. Options include a bag house air intakesystem, transport dolly system (FT6203 models), blending gates,dust suppression nozzles, and plumbing. At the heart of themachine, is an industry leading Vibrating Screen, which is anestablished industry leader with conventional aggregateproducers.

Application: Fast Trax® Screen Plants are typically used asscalping devices for fines elimination or oversize reject, as well asfinishing screens for final separation of finished products. Screencapacity depends on the feed characteristics and screen wireopening used. The maximum feed size is limited to 10” onstandard models and up to 18” on heavy scalping screens. Themaximum top deck screen opening is 4” or at just below the pointwhere large particles do not plug the openings. The minimumbottom deck opening is generally considered to be #8 meshdepending on material characteristics. For operating parametersoutside these guidelines contact.

FAST TRAX® SCREEN PLANTS

Page 84: Facts Figures Book

WASHINGINTRODUCTION

Clean aggregates are important to the constructionindustry. Yet producers of aggregates frequently arehard-pressed to meet all requirements for "cleanli-ness". Materials Engineers constantly strive to improveconcrete and bituminous mixes and road bases. Whilehydraulic methods are the most satisfactory for clean-ing aggregates to achieve the desired result, they arenot always perfect. It is still necessary to accept mate-rials on the basis of some allowable percent ofdeleterious matter.

In the broadest terms, construction aggregates arewashed to make them meet specifications. Specifi-cally, however, there is more to the function of water inprocessing aggregates than mere washing. Amongthese functions are:

1. Removal of clay and silt.2. Removal of shale, coal, soft stone, roots,

twigs, and other trash.3. Sizing.4. Classifying or separating.5. Dewatering.

Because no washing method can be relied upon to beperfect, and because some materials may require toomuch time, equipment, and water to make them con-form to specifications, it is not always economicallypractical to use such materials. It is important, there-fore, to test the source thoroughly beforehand toensure the desired finished aggregates can be pro-duced at reasonable cost. The project materialsengineer can be of immeasurable help in determiningthe economic suitability of the material, and generallymust approve the source before production begins,anyway. Further, many manufacturers of washingequipment will examine and test samples to determinewhether their equipment can do the job satisfactorily.No reputable equipment manufacturer wants to rec-ommend his equipment where he has a reasonabledoubt about its satisfactory performance on the job.

84

Page 85: Facts Figures Book

The ideal gradation is seldom, if ever, met in naturallyoccurring deposits. Yet the quality and control of thesegradations is absolutely essential to the workability anddurability of the end use. Gradation, however, is acharacteristic which can be changed or improved withsimple processes and is the usual objective of aggre-gate preparation plants.

Crushing, screening, and blending are methods usedto affect the gradations of aggregates. However, evenfollowing these processes, the material may stillrequire washing to meet specification as to cleanli-ness. Also, screening is impractical smaller than No. 8mesh and hence, hydraulic separation, or classifying,becomes an important operation.

Washing and classifying of aggregates can be consid-ered in two parts, depending on the size range ofmaterial.

Coarse material - generally above 3/8" (sometimessplit at 1/4" or #4 mesh). In the washing process itusually is desired to remove foreign, objectionablematerial, including the finer particles.

Fine aggregates - from 3/8" down. In this case it gen-erally is necessary to remove dirt and silt whileretaining sand down to 100 mesh, or even 200 mesh.

85

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GRADATION OF AGGREGATES

This term is used to denote the distribution of sizes ofthe particles of aggregates. It is represented by aseries of percentages by weight of particles passingone size of sieve but retained by a smaller size. Thedistribution is determined by a mechanical analysisperformed by shaking the aggregate through a seriesof nested sieves or screens, in descending order ofsize of openings. Round openings are used for largerscreens, square ones for the smaller sieves. Pre-scribed methods and prescribed openings of thescreens and sieves have been established by theASTM (American Society for Testing Materials). Thenormal series of screens and sieves is: 11⁄2", 3⁄4", 3⁄8",Numbers 4, 8, 16, 30, 50, 100, 200 mesh.

86

SIEVES FOR TESTING PURPOSESScreen or Sieve Nominal Opening EquivalentsDesignation mm inches microns

4" 101.63" 76.22" 50.811⁄2" 38.11" 25.43⁄4" 19.11⁄2" 12.73⁄8" 9.521⁄4" 6.35No.4 4.76 0.187 47606 3.36 0.132 33608 2.38 0.0937 238012 1.68 0.0661 168016 1.19 0.0469 119020 0.84 0.0331 84030 0.59 0.0232 59040 0.42 0.0165 42050 0.297 0.0117 29770 0.210 0.0083 210100 0.149 0.0059 149140 0.105 0.0041 105150 0.100 0.0039 100200 0.074 0.0029 74270 0.053 0.0021 53400 0.037 0.0015 37

Page 87: Facts Figures Book

87

Amou

nts Fine

r tha

n Ea

ch Lab

oratory Sieve (S

quare-Ope

ning

s), W

eigh

t Percent

Normal Size

Size

(Sieves with

4 in.

31⁄2i

n.3 in.

21⁄2i

n2 in.

11⁄2i

n.1 in.

3 ⁄4in.

1 ⁄2in.

3 ⁄8in.

No. 4

No. 8

No. 16

Num

ber

Squa

re Ope

ning

s)(100

mm)

(90 mm)

(75 mm)

(63 mm)

(50 mm)

(37.5 mm)

(25.0 mm)

(19.0 mm)

(12.5 mm)

(9.5 m

m)

(4.75 mm)

(2.36 mm)

(1.18 mm)

131⁄ 2t

o 11⁄ 2in.

100

90 - 10

025

- 60

0 - 1

50 - 5

(90 to 37.5 mm)

221 ⁄2

to 1

1 ⁄2in.

100

90 - 10

035

- 70

0 - 1

50 - 5

(63 to 37.5 mm)

32 to 1 in

.10

090

- 10

035

- 70

0 - 1

50 - 5

(50 to 25.0 mm)

357

2 in to

No. 4

100

95 - 10

035

- 70

10 - 30

0 - 5

(50 to 4.75 mm)

411 ⁄2

to 3 ⁄4

in.

100

90 - 10

020

- 55

0 - 1

50 - 5

(37.5 to 19.0 mm)

467

11 ⁄2in to

No. 4

100

95 - 10

035

- 70

10 - 30

0 - 5

(37.5 to 4.75 mm)

51 to 1 ⁄2

in.

100

90 - 10

020

- 55

0 - 1

00 - 5

(25.0 to 12.5 mm)

561 to 3 ⁄8

in.

100

90 - 10

040

- 85

10 - 40

0 - 1

50 - 5

(25.0 to 9.5 m

m)

571 in. to No. 4

100

95 - 10

025

- 60

0 - 1

00 - 5

(25.0 to 4.75 mm)

63 ⁄4

to 3 ⁄8

in.

100

90 - 10

020

- 55

0 - 1

50 - 5

(19.0 to 9.5 m

m)

673 ⁄4in. to No. 4

100

90 - 10

020

- 55

0 - 1

00 - 5

(19.0 to 4.75 mm)

71 ⁄2in. to No. 4

100

90 - 10

040

- 70

0 - 1

50 - 5

(12.5 to 4.75 mm)

83 ⁄8in. to No. 8

100

85 - 10

010

- 30

0 - 1

00 - 5

(9.5 to

2.36 mm)

GR

ADIN

G R

EQU

IREM

ENTS

FO

R C

OAR

SE A

GG

REG

ATES

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88

Often referred to sand specifications are ASTM C-33for concrete sand and ASTM C-144 for mason sand.These specifications are often written numerically andalso shown graphically.

Limits Center specSieve % Passing % Passing

3⁄8” 100 100No. 4 95-100 97.5

8 80-100 9016 50-85 67.530 25-60 42.550 5-30 17.5

100 0-10 5200 0-3 1.5

ASTM C-144

Limits Center specSieve % Passing % Passing

3⁄8” 100 100No. 4 100 100

8 95-100 97.516 70-100 8530 40-75 57.550 10-35 22.5

100 2-15 8.5200 0-10 5

SAND SPECIFICATIONS

ASTM C-33

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89

ASTM

C-3

3

100

3/8

1/4

46

810

12

16

20

30

40

50

70

80

100

140

200

9.5

6.3

4.7

53.3

52.3

62.0

1.7

1.1

8850 µ

M600

425

300

212

180

150

106

75

0.3

75

U.S

.

MM

DE

CIM

AL

0.2

50

0.1

87

0.1

32

.0937

.078.0

66

.0469

.0331

.0234

.0165

.0117

.0083

.0070

.0059

.0041

.0029 90

80

70

60

50

40

30

20

100

0

10

20

30

40

50

60

70

80

90

100

PERCENT PASSING

PERCENT PASSING

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90

ASTM

C-1

44

10

0

46

81

01

21

62

03

04

05

07

08

01

00

14

02

00

4.7

53

.35

2.3

62

.01

.71

.18

85

0 µ

M6

00

42

53

00

21

21

80

15

01

06

75

U.S

.

MM

DE

CIM

AL

0.1

87

0.1

32

.09

37

.07

8.0

66

.04

69

.03

31

.02

34

.01

65

.011

7.0

08

3.0

07

0.0

05

9.0

04

1.0

02

9

90

80

70

60

50

40

30

20

100

0

10

20

30

40

50

60

70

80

90

10

0

PERCENT PASSING

PERCENT PASSING

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FM AND SE

91

The factor called Fineness Modulus (FM) which iscommonly used, serves as a quick check that a givensample meets specifications without checking eachsieve size of material against the standards set for aparticular job. FM is determined by adding the cumu-lative 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 64#50 15 85#100 4 96

308 / 100 = 3.08 (FM)

Different agencies will require different limits on theFM. Normally, the FM must be between 2.3 and 3.1 forASTM C-33 concrete sand with only 0.1 variation for allthe material used throughout a certain project.

The Sand Equivalent Test (SE) is more complex thanthe FM test. The "equivalent" refers to the equivalentquantities of fine vs coarse particles in a given sandsample. The test is performed by selecting a givenquantity of a sand sample and mixing it in a specialsolution. The chemicals in the solution contain excel-lent wetting agents. These wetting agents will rapidlydissolve any deposits of semi-insoluble clays or plasticclays, which are clinging to the individual sand parti-cles. After a specified period of agitation, either byhand or by machine, the sample is allowed to stand ina graduated tube for a specified time period. Aweighted plunger is slowly lowered into the settledsand-solution mixture, and the depth to which theweight descends is noted from the graduations on thetube. A formula is supplied with the testing apparatus,and from that formula the "SE" is determined.

Page 92: Facts Figures Book

COARSE MATERIAL WASHING

In order to produce aggregate at the most economicalcost, it is important to remove, as soon as possible,from the flow of material, any size fraction that can beconsidered ready for use. The basic process consistsof crushing oversize material, scrubbing or washingcoatings or entrapped materials, sorting and dewater-ing. Beneficiation of some coarse aggregate fractionsmay be necessary. When scrubbing or washing ofcoarse material is required, it is generally a considera-tion of the material size, the type of dirt, clay or foreignmaterial to be scrubbed and the Tons Per Hour rateneeded that will determine the coarse material wash-ing equipment to use.

92

In general, the finer the sand, the deeper the weightwill penetrate. The wetting agents, that dissolve theclay, make a seemingly coarse material much finerbecause the clays are now a separate, very fine prod-uct. This extra fine material acts as a lubricant and theweight will descend deeper in the sample. Because ofthis, it is possible that a sample with an acceptable FMis rejected for failure to pass the SE test.

Page 93: Facts Figures Book

Purpose: In the aggregate business, the log washeris known best for its ability to remove tough, plastic sol-uble clays from natural and crushed gravel, crushedstone and ore feeds. The log washer will also removecoatings from individual particles, break up agglomer-ations, and reduce some soft, unsound fractions by aform of differential grinding.

Design: The log washer consists of a trough or tank ofall welded construction set at an incline (typically 6-10°) to decrease the transport affect of the paddlesand to increase the mass weight against the paddles.Each “log” or shaft (two per unit) is fitted with four rowsof paddles which are staggered and timed to allow thepaddles of each shaft to overlap and mesh with thepaddles of the other shaft. The paddles are pitched toconvey the material up the incline of the trough to thedischarge end.

93

LOG WASHERS

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Log washer design improves on the traditional designin that the paddles are set in a spiral pattern aroundthe shaft instead of in a straight line as in competitiveunits. This design feature provides many benefitsincluding: 1) Reduces intermittent shock loading of thelog, 2) Keeps a portion of the mass in motion at alltimes thus reducing power peaks and valleys as wellas overall power requirements, 3) Reduces wear and4) Provides more effective scrubbing. Other importantfeatures of the log washer include two (2) large tankdrain/clean-out ports, rising current inlet, overflowports on each side of the unit, cast ni-hard paddleswith corrugated faces, readily available externallymounted lower end bearings and a custom designedand manufactured single input dual output gearreducer.

Application: The majority of the scrubbing action per-formed by the log washer is accomplished by theabrading action of one stone particle on another, not bythe action of the paddles on the material. Due to thisand other feed material characteristics such as claysolubility, the capacity of a log washer is given in afairly wide range. Normal practice is to follow the logwasher with a screening device on which spray barsare used to remove fines and clay coatings on thestone.

94

Water Maximum Approx. Approx.Capacity Motor Req’d. Feed Size Dead Load Live Load

Model (TPH) (HP) (GPM) (in.) (lbs.) (lbs.)

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

LOG WASHERS

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COARSE MATERIAL WASHERS

95

Purpose: The coarse material washer is used toremove a limited amount of deleterious material from acoarse aggregate. This deleterious material includesshale, wood, coal, dirt, trash and some very solubleclay. A coarse material washer is often used as finalwash for coarse material (typically -21⁄2" x +3⁄8") follow-ing a wet screen. Both single and double spiral unitsare available depending on the capacity required.

Design: The coarse material washer consists of a longvertical sided trough or tank of all welded constructionset at a 15° incline. The shaft(s) or spiral(s) of a coarsematerial washer begin with one double pitch spiralflight with replaceable ni-hard outer wear shoes andAR steel inner wear shoes. Following this single flightis a variable number of bolt-on paddle assemblies.Standard units include four (4) sets of paddle armswith ni-hard tips. Two (2) sets of arms replace one fullspiral. The balance of the spiral(s) consists of doublepitch spiral flights with replaceable ni-hard outer wearshoes and AR steel inner wear shoes.

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Other important features of the coarse material washerinclude a rising current manifold, adjustable full widthoverflow weirs, readily available externally mountedlower end bearing(s) and upper end bearing(s) andshaft mounted gear reducer with v-belt drive assembly(one drive assembly per spiral).

Application: As previously noted, the number of pad-dle assemblies can be varied. The number of paddleassemblies installed on particular unit is dependent onthe amount of water turbulence and scrubbing actionrequired to suitably clean the feed material. As thenumber of paddles is increased, the operational char-acteristics of the unit change including increasedscrubbing action, increased retention time, reducedcapacity and increased power requirements.

96

Approx. Approx.Water Dead Live

Capacity Motor Req’d. Load LoadModel (TPH) (HP) (GPM) (lbs.) (lbs.)

SINGLE SPIRAL CONFIGURATIONS:

6024-15S 60-75 15 300-400 6,200 9,000

6036-19S 150-175 25 400-600 10,400 19,000

6048-23S 200-250 40 500-700 15,600 38,500

TWIN SPIRAL CONFIGURATIONS:

6036-19T 300-350 25 700-900 17,000 37,000

6048-23T 400-500 40 800-1000 28,500 78,000

NOTE: Two (2) motors required on twin units. 24" diameter unit offered onlyin single spiral configuration.

COARSE MATERIAL WASHERS

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BLADEMILLS

97

Purpose: Similar in design to the Series 6000 CoarseMaterial Washer, the blademill is used to pre-conditionaggregates for more efficient wet screening. Blademillsare generally used prior to a screening and washingapplication to break up small amounts of soluble mudand clay. Typical feed to a blademill is 21⁄2" x 0". Unitsare available in both single and double spiral designsdepending on the capacity required.

Design: The blademill consists of a long vertical sidedtrough or tank of all welded construction set at a vari-able incline (typically 0-4°) depending on the degree ofscrubbing or pre-conditioning required. The shaft(s) orspiral(s) of a blademill begin with one double pitch spi-ral flight with replaceable ni-hard outer wear shoes andAR steel inner wear shoes. Following this single flightis a combination of bolt-on paddle and flight assem-blies, which can be varied, depending on the amountof scrubbing required. The flight assemblies includereplaceable ni-hard outer wear shoes and AR steelinner wear shoes. The paddle assemblies are fittedwith replaceable cast ni-hard paddle tips. Other impor-tant features of the blademill include readily availableexternally mounted lower end bearing(s) and upperend bearing(s) and shaft mounted gear reducer with v-belt drive assembly (one drive assembly per spiral).

Page 98: Facts Figures Book

Application: The number of paddle and flight assem-blies as well as the angle of operation can be varieddependent upon the amount of scrubbing or pre-con-ditioning required. Also, as the number of paddles orangle of operation is increased, the operational char-acteristics of the unit change including increasedscrubbing action, increased retention time, reducedcapacity and increased power requirements.

Capacities/Specifications: Blademill capacity is indi-rectly a function of retention time. Each application willindicate a required period of time for effective washing,which actually determines the capacity of the unit. As arule of thumb, a blademill can be expected to processin the range of a coarse material washer with respectto raking capacity in TPH and requires approximately1⁄4 to 1⁄3 of the water required in a coarse materialwasher. If sufficient information is not available withregards to clay content and solubility, the lower end ofthe coarse material washer range should be used.Blademills are offered in single or twin screw configu-rations of the same size as coarse material washers.

98

Approx. Approx.Water Dead Live

Capacity Motor Req’d. Load LoadModel (TPH) (HP) (GPM) (lbs.) (lbs.)

SINGLE SPIRAL CONFIGURATIONS:

6524-15S 60-75 15 75-150 6,900 7,500

6536-19S 150-175 25 100-200 11,100 15,800

6548-23S 200-250 40 125-250 17,700 30,700

TWIN SPIRAL CONFIGURATIONS:

6536-19T 300-350 25 175-350 18,400 28,300

6548-23T 400-500 40 200-400 32,900 57,600

NOTE: Two (2) motors required on twin units. 24" diameter unit offered onlyin single spiral configuration.

BLADEMILLS

Page 99: Facts Figures Book

FINE MATERIAL WASHINGAND CLASSIFYING

INTRODUCTION

Aside from washing sand to remove dirt and silt,hydraulic methods are employed to size the materialand to classify or separate it into the proper particledesignation. After these steps, it is usual procedure todewater the product.

Washing aggregates to clean them is not new. How-ever, much closer attention has been given to both thecleanliness and the gradation of the fines in construc-tion aggregates. Thus has developed a new "art" in theprocessing of fine aggregates. This "art" requires moretechnical know-how and methods more precise thanthose usually associated with the mere washing ofgravel and rock. At the same time, it has been neces-sary to advance the art in a practical way so as toproduce material at a reasonable price.

Screening is the best way to separate coarse aggre-gates into size ranges. With fine materials, however,screening on less than No. 8 mesh usually is impracti-cal. This necessitates a split between 3⁄8" and #4 meshputting everything finer into the category of requiringhydraulic separation for best gradation control.

With hydraulic separation, a large amount of water isused. Here separation depends on the relative buoy-ancy’s of the grain particles and on their settling ratesunder specific conditions of water flow and turbulence.In some cases, separation depends on the relativespecific gravity difference between the materials to beseparated and the hydraulic medium. In a certainsense, this applies when water is used to separate par-ticle sizes of sands. Perhaps it would be more apt tosay this separation of sands is based on relative den-sities or that the process separates by gravity.

99

Page 100: Facts Figures Book

In its strictest sense, however, classifying means thatseveral sizes of sand products of equal specific grav-ity can be separated while rejecting slimes, silt, andsimilar deleterious substances. But sand particles arenot necessarily always of the same specific gravity, sofrequently both specific gravity and particle size affectthe rate of settling. As a consequence, you cannotalways estimate the probable gradation of the finalproducts without preliminary tests on the material. Norcan you be sure of product quality without analysis andtests after processing.

In any hydraulic classification of sand, the amount offines retained with the final product will be dependentupon:

1. Area of settling basin.2. Amount of water used.3. Extent of turbulence in settling area.

Obviously, the area of the settling basin generally willbe fixed. Hence the amount and size of fines to berejected will be determined by regulating the waterquantity and turbulence.

100

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Purpose: Fine material washers, also frequentlycalled screw classifiers or screw dehydrators, are uti-lized to clean and dewater fine aggregates (typically–3⁄8" or -#4 mesh), fine tune end products to meet spec-ifications and to separate out slimes, dirt and fines(typically -#100 mesh or finer). Available in both singleand twin configurations, fine material washers aremost often used after a sand classifying/blending tankor after a wet screening operation.

Design: The fine material washer consists of an allwelded tub set at an incline of approx. 18.5° (4:12slope) and includes a full length curved bottom withintegral rising current manifold designed to controlfines retention and the water velocity within the pool.The lower end of the tub or tank is flared to provide alarge undisturbed pool, which provides accurate mate-rial classification. Long adjustable weirs around the topof the sides and end of the tub’s flared portion aredesigned to handle large volumes of slurry and to con-trol the pool level for uniform overflow. Alsoincorporated into the design of the tub is a chase waterline to clear the drain trough for better dewatering andan overflow flume.

101

FINE MATERIAL WASHERS

Page 102: Facts Figures Book

The shaft(s) or spiral(s) of the fine material washerconsist of a double pitch, solid flight spiral, completewith AR steel inner wear shoes and urethane outerwear shoes, to provide protection of the entire flight(cast ni-hard outer wear shoes are optional). Otherimportant features of the Fine Material Washer includereadily available externally mounted lower end bear-ing(s) and upper end bearing(s), shaft mounted gearreducer with v-belt drive assembly (one drive assem-bly per spiral), and center feed box with internal andexternal baffles to reduce the velocity of the materialentering the fine material washer, and reduce pool tur-bulence, enhancing fines retention.

Application: Two important elements must be consid-ered when sizing a fine material washer for a particularapplication: 1) calculation of overflow capacities and 2)calculation of sand raking capacity. Overflow capacityis critical to ensure that the unit has sufficient capacityto handle the water required for proper dilution of thefeed material which allows for proper settling to occurand to produce the desired split point. The rakingcapacity of a fine material washer is governed by thefineness of the material to be dewatered. Generallyspeaking, the finer the material to be raked, the slowerthe spiral speed must be, to ensure adequate dewa-tering and reduced pool turbulence. The followingtables are provided to assist in the proper selection ofa fine material washer.

102

% SCREW SPEED % PASSING % PASSING % PASSING(RPM) 50 MESH 100 MESH 200 MESH

100% 15 2 0

75% 20 5 0

50% 30 10 3

25% 50 25 8

PERCENT SCREW SPEED vs. PERCENT FINES(in the product)

Page 103: Facts Figures Book

CAPACITY MINIMUM OVERFLOW CAPACITIESSINGLE/ % SCREW SPIRAL MOTOR HP (GPM)TWIN SPEED SPEED REQ’D/ SINGLE/TWIN

MODEL (TPH) (RPM) (RPM) SPIRAL 100 MESH 150 MESH 200 MESH

50 100% 32 7.5*5024-25 37 75% 24 5 500 225 125

25 50% 16 512 25% 8 3

75 100% 25 10*5030-25 55 75% 19 10 550 275 150

38 50% 13 7.518 25% 7 5

100/200 100% 21 155036-25 75/150 75% 15 10 700/1200 325/600 175/300

50/100 50% 12 7.525/50 25% 6 5

175/350 100% 17 205044-32 130/260 75% 13 15 1500/2700 750/1300 400/750

85/170 50% 9 1045/90 25% 5 7.5

200/400 100% 16 205048-32 150/300 75% 12 15 1650/2900 825/1450 450/825

100/200 50% 8 1050/100 25% 4 7.5

250/500 100% 14 305054-34 185/370 75% 11 25 1800/3200 900/1600 525/900

125/250 50% 7 1560/120 25% 4 10

325/650 100% 13 305060-35 250/500 75% 9 25 2200/3600 1000/1800 550/950

165/330 50% 5 2085/170 25% 3 15

400/800 100% 11 405066-35 300/600 75% 8 30 2400/4000 1100/2000 625/1000

200/400 50% 5 25100/200 25% 3 15

475/950 100% 11 605072-38 355/710 75% 8 50 2600/4400 1250/2200 700/1200

235/475 50% 5 30120/240 25% 3 15

103

FINE MATERIAL WASHERSRAKING & OVERFLOW CAPACITY TABLE

NOTE: Two (2) motors required on twin units. *24" & 30" dia. units offered only in single spiral configuration.

Page 104: Facts Figures Book

FIN

E M

ATER

IAL

WAS

HER

WEI

R O

VER

FLO

W R

ATES

104

NO

TE:All flows sh

own are in gpm

. Bol

d ita

liciz

edflo

ws de

pict overflow ra

tes

requ

ired for 2

00, 1

50 &

100

mesh sp

lits resp

ectiv

ely.

AVER

AG

E D

EPTH

OVER

WEIR

MO

DEL

WEI

R L

ENG

TH1 ⁄ 4"

1 ⁄ 2"3 ⁄ 4"

1"11 ⁄ 4"

11 ⁄ 2"13 ⁄ 4"

2"21 ⁄ 4"

21 ⁄ 2"12

5

22

5

500

5024

-25S

15'3"

9222

9

397

564

717

991

1205

14

4916

7819

8315

0

2

75

5

5050

30-25S

15'9"

9523

641

058

374

010

2412

44

1496

1733

2048

17

5

32

5

7

0050

36-25S

16'3"

9824

442

3 60

176

4 10

5612

84

1544

1788

2113

300

6

00

120

050

36-25T

19'9”

119

296

514

731

928

1284

15

6018

7621

7325

6840

0

7

50

1500

5044

-32S

22'0"

132

330

572

814

1034

1430

1738

2090

2420

2860

750

1

300

2

700

5044

-32T

26'0"

156

390

676

962

1222

1690

2054

2470

2860

3380

450

825

165

050

48-32S

22'3"

134

334

579

823

1046

1446

1758

2114

2448

2893

825

14

50

290

050

48-32T

26'9"

160

401

696

990

1257

1739

2113

2541

2943

3478

525

900

1

800

5054

-34S

26'0"

156

390

676

962

1222

16

90

2054

24

7028

6033

8090

0

160

0

32

0050

54-34T

31'0"

186

465

806

1147

14

5720

1524

49

2945

3410

4030

550

1

000

2200

5060

-35S

26'6"

159

398

689

981

1246

1723

2094

2518

2915

3445

950

180

0

3600

5060

-35T

31'6"

189

473

819

1166

1481

2048

2489

2993

3465

4095

625

110

0

240

050

66-35S

27'3"

164

409

709

1008

1281

1771

2153

25

8929

9835

4310

00

2000

400

050

66-35T

32'9"

197

491

852

1212

15

39

2129

2587

3111

3603

4258

700

1

250

260

050

72-38S

27'9"

167

416

722

1027

13

04

1804

2192

2636

3053

3608

1200

2200

440

050

72-38T

34'3"

206

514

891

1267

16

10

2226

2706

3254

3768

4453

Page 105: Facts Figures Book

CLASSIFICATION METHODSAPPLIED TO FINE AGGREGATES

INTRODUCTION

Classification is the sizing of solid particles by meansof settling. In classification, the settling is controlled sothat the very fines, silts and clays will flow away with astream of the water or liquid, while the coarse particlesaccumulate in a settled mass.

Washing/classifying equipment is manufactured inmany different configurations depending on the naturalmaterial characteristics and the end product(s)desired. Although the general definition of aggregateclassifying can be applied to coarse material (+3⁄8"), it ismost commonly applied to the material passing 3⁄8".Included in the fine material classifying equipment arethe sand screws, counter-current classifiers, sanddrags and rakes, hydro-cyclones, hydro-classifiers,bowl classifiers, hydro-separators, density separators,and scalping/classifying tanks.

All the above mentioned classifiers, except the scalp-ing/classifying tank, are generally single productmachines which can only affect the gradation of theend product on the very fine side (the overflow sepa-ration size). This separation size, due to the mechani-cal means employed, is never a knife-edge separation.However, the aim of modern classification methods isto approach a clean-cut differentiation. Many materialspecifications today call for multiple sizing of sand withprovisions for blending back to obtain the gradationsrequired. It is rare to find the exact blend occurring nat-urally or to economically manufacture the blend toexact specifications. In either case, the accepted pro-cedure is to screen out the fine material from which thesand specifications will be obtained. This material isprocessed in a water scalping/classifying tank for mul-tiple separation by grain sizes or particle specificgravity.

There is no mystery connected with classifying tanks.They are merely long settling basins capable of hold-ing large quantities of water. The water and sand mix

105

Page 106: Facts Figures Book

(slurry) is introduced into the tank at the feed end. Theslurry, which often comes from dredging or wet screen-ing operations, flows toward the overflow end, and asit does, solids settle to the bottom of the tank. Weightdifferences between sand particles allow coarsermaterial to settle first while lighter material progres-sively settles out further along the tank length.

PRINCIPLES OF SETTLING

The specific gravity of aggregates varies according tothe nature of the minerals in the rock. "Bulk" specificgravity is used in aggregate processing and indicatesthe relative weight of the rock or sand, including thenatural pores, voids and cavities, as compared towater (specific gravity = 1.0). In the case of fine aggre-gates, the specific gravity is about 2.65. As aconsequence, the weight of grains of sand will bedirectly proportional to their volume. All grains of sandof a given size will therefore weigh the same, and theweight can be measured in relation to the opening ofthe sizing sieve.

A second basic consideration is that of the density orspecific gravity of the slurry itself. Dilution is usuallyexpressed in percentages by weight of either the solid,or, of the water. Since the specific gravity of water is1.00 and that of sand is assumed to be 2.65, a simplecalculation will give the specific gravity, or density, ofthe slurry mixture.

CALCULATION OF SLURRY OR PULP

106

The following method of calculating slurry or pulp isquick, accurate and requires no reference tables. Itmay be used for any liquid-solid mixture.

Basic equation, for a single substance or mixture:

GPM = TPH x SG

For Water: GPM Water = TPH Water x 4

For Solids: GPM Solids = TPH Solids x SG Solids

4

4

Page 107: Facts Figures Book

For Solids SG 2.65-2.70 (sand, gravel, quartz, lime-stone): GPM Solids = TPH Solids x 1.5

For Slurry: GPM Slurry = TPH Slurry x SG Slurry

To solve for Specific Gravity:

SG Slurry = GPM Slurry

Example:Given: 10 TPH of Sand @ 40% Solids (by weight)Find: GPM and SG of SlurryUse this matrix to calculate your data

107

4

TPH Slurry x 4

% Weight TPH SG GPM

Water 1.0

Solids 40 10 2.67

Slurry 100

% Weight TPH SG GPM

Water 60 15 1.0 60

Solids 40 10 2.67 15

Slurry 100 25 1.33 75

Fill in as follows:1) Convert % Weight to decimel form: 40% = 0.402) TPH Slurry = TPH solids divided by 0.40 = 253) TPH Water = TPH Slurry - TPH Solids = 154) GPM Water = TPH Water x 4 = 605) GPM Solids = TPH Solids x 1.5 = 156) GPM Slurry = GPM Water + GPM Solids = 757) SG Slurry = TPH Slurry x 4/GPM Slurry = 1.33

The tablulation can be solved for all unknowns if SGSolids and two other principal quantities are given.

If GPM Slurry, % Solids and SG Solids are given, solvefor 1 TPH and divide total GPM Slurry by resultantGPM Slurry to obtain TPH Solids.

Rework tabulation with this figure to check the result.

Percent Solids by Volume may be calculated directlyfrom GPM column.

Page 108: Facts Figures Book

GPM column may also be extended to any other unitdesired; e.g., Cu. Ft. per Second.

NOTE:1) The equation is based on U.S. Gallon and std. (short)

ton of 2000 lbs.2) The difference in result by using 2.65 or 2.70 SG Solids

is negligible compared to the inaccuracy usually inher-ent in given quantities.

3) For sea water, use SG 1.026. In this case, the differenceis appreciable.

108

CONVERSION FACTORS

To Obtain Multiply By Based OnTPH Cu. Yd/Hr. 1.35 Sand 100#/cu. ft., dry.Short TPH Long TPH 1.12 2240 lb. tonShort TPH Metric TPH 1.1023 Kilo = 2.2046 lb.U.S. GPM British GPM 1.201U.S. GPM Cu. Ft./Min. 7.48U.S. GPM Cu. Ft./Sec. 448.5

The third consideration is that of viscosity. Viscositycan be compared to friction in that it is a resistance tomovement between liquid particles and between solidand liquid particles.

In a continuous process, such as in the production offine aggregates, the slurry flows into and out of theclassifying tank at a measurable rate, which deter-mines its velocity of flow through the tank. The solidssettle out, due to their weight, at a speed that isexpressed as rate of fall or settling. It is the interrela-tionship between these two movements which governsthe path of the falling particle.

GA

LALB

LCLD

LE

B C

OVERFLOW

PATH OF PARTICLE

HORIZONTAL TRAVEL OF FALLING SAND PARTICLES

DIAGRAM OF FORCES

D

Settling From A Surface Current

D

FEED

E

VO

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

Page 109: Facts Figures Book

While a particle is in suspension, one force acts on it tomake it fall, while others act to retard the fall. The forcethat acts downward is that of gravity (g). It has beenbrought out that viscosity of the liquid may retard thefall. The difference between free settling and hinderedsettling is a relative one between the factors causing aparticle to fall and those retarding the fall. In free set-tling, the downward component is much greater thanthose slowing up the fall are. In hindered settling, thedownward component is only slightly greater thanthose slowing the fall are.

Apart from the multiple sizing, the scalping tank servesto eliminate the surplus water prior to discharge ofproduct to a screw-type classifier. By so doing, theamount of water handled by the screw classifier can beregulated better for the mesh size of fines to beretained. It becomes apparent, then, that a waterscalping tank will be followed by as many screw clas-sifiers as there are sizes of sand products to be made.

Adjustable weirs on the scalping tank regulate the rateand velocity of overflow to provide the size separationsrequired. Clays, silt and slime which are lighter thanthe finest mesh sand, remain suspended in the waterand are washed out over the tank weirs for dischargeinto a settling pond.

In order to re-blend sand fractions into a specificationproduct, settling stations are located along the bottomlength of the tank. The best classifying occurs withmore length to the classifying tank. It is recommendedto use a minimum of a 28' tank. Shorter tanks will workwhen the material is very consistent in gradation andclose to the product specification to be made.

Build up or "silting in" of the classifying tank will occuras the specific gravity of the overflow slurry goesbeyond 1.065. The ideal slurry is between 1.025 and1.030. At this point maximum efficiency occurs.Additional water will carry away more fines unless thetank area is oversized.

109

Page 110: Facts Figures Book

110

0 10 20 30 40 50 60 70 80

0 10 20 30 40 50 60 70 80

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

SP

EC

IFIC

GR

AV

ITY

SL

UR

RY

OR

PU

LP

(G

)

SP

EC

IFIC

GR

AV

ITY

SL

UR

RY

OR

PU

LP

(G

)

DENSITY PERCENT SOLIDS

DENSITY PERCENT SOLIDS

G=

=

1000WT 1 LITER SLURRY IN GRAMS

DENSITY % SOLIDS BY WEIGHT

G160 (G-1)

=DENSITY % SOLIDS BY VOLUME

60 (G-1)

FOR THE ABOVE MATERIALS

FOR G = 1.25

DENSITY = 32% SOLIDS BY WT

OR 15% SOLIDS BY VOL

EXAMPLE

FOR

SO

LID

S B

Y W

EIG

HT

FOR

SO

LID

S B

Y VO

LUM

E

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

DENSITY—SPECIFIC GRAVITY RELATIONSHIPFOR WATER SLURRY OF SAND, GRAVEL,

QUARTZ OR LIMESTONE(SOLID S.G. 2.65-2.70)

Page 111: Facts Figures Book

111

SAND CLASSIFYING TANKS

Purpose: Classification is the sizing of solid particles(typically –3⁄8" or -#4 mesh) by means of settling. Inclassification, the settling is controlled so that the finesor undersize material will flow away with a stream ofwater or liquid, while the coarse or oversize materialaccumulates in a settled mass. By applying the princi-ples of settling and classification in the classifying/water scalping tank, the following functions are per-formed:1) Reject undesirables – remove clay, silts, slime andexcess fine particles.

2) Separate desirable sand particles so that they canbe controlled.

3) Reblend separated material into correct gradationspecifications.

4) Production of two different specification productssimultaneously and an excess product.

5) Remove excess water.

Feed to a classifying tank is typically in the form of asand and water slurry. The slurry feed can come fromseveral sources, but is generally from a dredging orwet screening operation.

CLASSIFYING TANKS ARE NECESSARY WHEN ANY ONE OF THE FOLLOWING CONDITIONS EXIST:

1) Feed material gradations fail to meet the allowableminimums or maximums when compared to thematerial specifications to be produced.

2) Sand feed gradations vary within a deposit.3) More than one specification product is desired.4) Excessive water is present, such as from a dredgingoperation.

Page 112: Facts Figures Book

Design: A classifying tank consists of an all weldedtank of varying size ranging from 8' x 20' to 12' x 48'.The slurry feed is introduced into the tank through afeed box, which includes an integral curved liner forimproved slurry flow control. As the slurry flows towardthe discharge end of the tank, weight differencesbetween sand particles allow coarser material to settlefirst while the lighter material settles progressively fur-ther down the tank. Clays, silt and slime which arelighter than the finest mesh sand remain suspended inthe water and are washed out over the adjustable tankweirs for discharge into a settling pond. Sand fractionsare then reblended into two specification products andan excess product, via settling stations (six to elevendepending on tank length) located along the bottom ofthe tank. Discharge valves (typically three) at each sta-tion serve to “batch” the sand into a collecting/blending flume located below the tank.

112

Coarse Medium

FEED

A BC

VELOCITY CLASSIFICATION

Fine Very Fine

Water and Slime

Page 113: Facts Figures Book

Sand discharge is controlled via a controller (see sec-tion on Spec-Select™ Classifying Tank Controllers)which receives a signal from an adjustable heightsensing paddle located at each station. The sensingpaddle controls the amount of material that accumu-lates at each station before a valve opens to dischargethe sand and water slurry. The valves consist of self-aligning urethane dart valves and urethane seatsproviding uniform flow at the maximum rate, positivesealing and long service life. The urethane dart valve isconnected to an adjustable down rod to ensure opti-mum seating pressure and provide leak resistantoperation. The valves are activated by an electric/hydraulic mechanism in response to signals receivedfrom the controller and sensing paddle. Once dis-charged, the slurry flows through product down pipes,which include urethane elbows for improved flow andwear into a collecting/blending flume for transport tothe appropriate dewatering screw.

The electric/hydraulic mecha-nism is mounted within abridge that runs lengthwisewith the tank. This systemincludes an electric/hydraulicpump, reservoir, accumulator,individual ball, and checkvalves at each station. Alsoincluded is a toggle switchbox, with a 3-position switchfor each valve at a stationwhich can be “plugged in” toan individual station, provid-ing maximum flexibility introuble shooting and servicingthe Classifying Tank. Otherimportant features of the clas-sifying 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 waterrequirements and complete pre-wiring of the tank to aNEMA 4 junction box/control enclosure located on thebridge.

113

AB

C

Page 114: Facts Figures Book

Application: Several factors affect the sizing andapplication of a classifying tank. Among these are drymaterial feed rate, material density, feed gradation,product gradations or specifications desired, feedsource, the amount of water entering the tank with thefeed material and other material characteristics suchas whether the material is crushed or natural. Of thesefactors, four items must be known to properly size aclassifying tank:• Feed rate (TPH)?• Feed gradation?• Feed source?…..Conveyor? Dredge?• Product gradations or specifications desired?

Given the above, the classifying tank is sized based onits water handling capacity. The requirements for waterin a classifying tank are to have approximately 10 GPMof water for every 1 TPH of total sand feed or 100 GPMof water for every 1 TPH of silt (-#200 mesh). Thelarger of these two figures and the desired mesh splitto be produced within the tank are then used to sizethe classifying tank. This process allows for properdilution of the sand so that the material will correctlysettle in the tank for proper classification. The followingtable is provided to assist in the proper selection of aclassifying tank.

114

APPROX. APPROX. NUMBERDEAD LIVE OFLOAD LOAD WATER CAPACITIES (GPM) DISCHARGE

SIZE (LBS) (LBS) 100 MESH 150 MESH 200 MESH STATIONS

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.

CLASSIFYING TANKS

Page 115: Facts Figures Book

115

CLAS

SIFY

ING

TAN

K W

EIR

OVE

RFL

OW

RAT

ES

NO

TE:All flows sh

own are in gpm

. Bol

d ita

liciz

edflo

ws de

pict overflow ra

tes requ

ired for 2

00, 1

50 &

100

mesh sp

lits resp

ectiv

ely.

AVER

AG

E D

EPTH

OVER

WEIR

MO

DEL

WEI

R L

ENG

TH1 ⁄ 4"

1 ⁄ 2"3 ⁄4"

1"11 ⁄ 4"

11 ⁄ 2"13 ⁄ 4"

2"21 ⁄ 4"

700

12

00

23

008' x 20'

32'

225

480

800

1150

1690

22

2527

2033

6044

0080

0

1400

2

800

8' x 24'

40'

280

600

1000

1440

2120

28

0034

00

4200

5000

900

160

0

3

200

8' x 28'

48'

336

720

1200

17

2025

5033

50

4070

50

4060

0095

0

1

800

3

500

8' x 32'

56'

392

840

1400

2010

2960

39

2047

50

5880

7000

950

1800

35

0010

' x 24'

42'

295

630

1050

1520

2230

2940

3570

4400

5250

1100

210

0

4100

10' x

28'

50'

350

750

1250

1800

2650

3500

42

50

5240

6250

1250

240

0

4700

10' x

32'

58'

410

880

1450

2080

30

6040

6049

30

6080

7250

1400

270

0

5300

10' x

36'

66'

465

990

1650

2380

3500

4630

56

10

6920

8250

1550

3000

59

0010

' x 40'

74'

520

1110

1850

2660

39

2051

8062

90

7760

9250

2150

4200

81

0012

' x 48'

80'

562

1200

2000

2876

42

38

5600

6800

83

9010

000

Page 116: Facts Figures Book

116

SPEC-SELECT™ CONTROLLERSPurpose:Spec-Select™Controllers are uti-lized in conjunctionwith a classifyingtank to control theblending of the vari-ous sand fractionsinto one or two spec-ification productsplus an excess prod-uct. Spec-Select™ Controllers are also a valuablesource of information when trouble shooting or simplymonitoring the activity occurring within a classifyingtank.

Design: Spec-Select™ Controllers consist of anindustrial quality solid-state PLC (Programmable LogicController) housed in the NEMA 4 junction box/controlenclosure located on the bridge of the classifying tankand a desk top PC (Personal Computer) HMI (human-machine interface). An optional industrial PC HMI withcolor touch screen housed in a NEMA 4 enclosure isalso available for outdoor installation in lieu of the desktop PC. Simple, windows based controls are used onall systems, allowing the operator to proportion theamount of material discharging from each station tothe appropriate collecting/blending flume for transportto the dewatering device. EEPROM memory in thePLC and the hard drive of the PC provide permanentstorage PLC logic, operating parameters, recipes andthe screens displayed on the HMI, which are used tocreate a user-friendly interface to the PLC, which actu-ally controls the classifying tank.

Application: Two modes of controlling the tank dis-charge are utilized in conventional classifying tanks.The Spec-Seclect™ I (SSI) mode of operation is thesimplest method to operate a classifying tank and isthe same in theory as the manual splitter box typeclassifying tanks. It is an independent control of eachstation by a percentage method to determine theamount of material discharged to each of the threeproduct flumes. The system operates on a 10-second

Page 117: Facts Figures Book

117

cycle that is repeated over and over from product “A”to “B” to “C”. The mode of operation works best in afairly consistent pit, where the feed gradation does notvary too much. Monitoring of the product gradationsinforms the operator of variances in the feed. Changesto the percentage settings at each station can be madequickly at the controller to maintain the product speci-fication.

The Spec-Select™ II (SSII) mode of operation is adependent method of operation utilizing minimum andmaximum timer settings at each station to control thematerial discharge, and ensure that product specifica-tions are met on a consistent basis. This system, notonly controls the discharge valves at each station, butalso controls all of the settling stations relative toeachother. The minimum and maximum timer settingsare determined by the gradation of the material settlingout at each station and relating this to the productspecification limits. In effect, the SSII mode of opera-tion is making batches of specification sandcontinuously. Each “A” or “B” valve at a given stationdischarges sand on a time basis between its minimumand maximum timer settings. No valve can begin anew batch until every other valve has discharged atleast its minimum in the present batch being made.When a valve reaches its maximum timer setting andone or more of the other valves for that product havenot yet met their minimum settings, the controller auto-matically directs the material to one of the otherproduct valves and flumes. It is important to remember,in this mode of operation, the potential to waste or todirect sand to a non-spec product where it is notdesired is increased and should be carefully consid-ered when operating a tank by this method. This modeof operation is typically used when the feed gradationand/or feed rate vary widely.

All currently manufactured models of Spec-Select™Controllers are capable of operating in either the Spec-Select™ I or the Spec-Select™ II mode of operation.

Page 118: Facts Figures Book

Purpose: Screening/washing plants are utilized to rinse andsize up to three stone products while simultaneously washing,dewatering and fine tuning a single sand product. Specificstone product gradations can typically be met with the use ofblending gates between the screen overs chutes while sandproduct gradations are adjusted with screw speed and wateroverflow rates.

Design: Traditional Series 1800 Screening/Washing Plantsconsist of a heavy duty three-deck incline (10°) or horizontalwet screen mounted above a Fine Material Washer on eithera semi-portable skid support structure or a heavy dutyportable chassis. Important features of the screening/washingplant include the capability to fit three radial stacking convey-ors under the screen overs chutes, complete water plumbingwith single inlet connection and wide three-sided screenaccess platform, as well as all the features of the industryleading Screens and the Fine Material Washers.

Also available are the Model #1822PHB and Model#1830PHB Portable Screening/Washing Plants which incor-porate a blademill ahead of the horizontal screen, all on asingle heavy duty portable chassis. This addition serves toprecondition the raw feed material for more efficient wetscreening.

Application: Review of the feed material gradation, productsdesired and TPH to be processed will determine the screenand screw combination best suited for the application.

118

SCREENING/WASHING PLANTS

Page 119: Facts Figures Book

119

1800 SERIESSCREENING/WASHING PLANTS

Model #1822 Model #1830Description Model #1814 Model #1822 Model #1830 PHB PHB

Screen Size 5' x 14' 6' x 16' 6' x 20' 6' x 16' 6' x 20'(inclined only) (horizontal only) (horizontal only)

Fine Material 44" x 32' twin orWasher Size 36" x 25' single 36" x 25' twin 36" x 25' twin 36" x 25” twin 44" x 32' twin

Blademill Size N/A N/A N/A 24" x 12' twin 36" x 15” twin

Plant Capacity Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory

Water Up to 700 Up to 1200 Up to 2700 Up to 1200 Up to 2700Requirements US-GPM US-GPM US-GPM US-GPM US-GPM

OPTIONAL EQUIPMENT (Portable and Skid Plants)

Wedge Bolts(for screen Yes Yes Yes Yes Yes

cloth retention)

AR or UrethaneChute & Hopper Yes Yes Yes Yes YesWear Liners

Feed/Slurry Box Yes Yes Yes Yes Yes

Wire MeshScreen Cloth Yes Yes Yes Yes Yes

Deck Preparationfor Urethane No Yes Yes Yes YesScreen Media

Electrical Pkg. Yes Yes Yes Yes Yes

Blending Gates Yes Yes Yes Yes Yes

OPTIONAL EQUIPMENT (Skid Plants only)

Stair Access vs.Ladder Access Yes Yes Yes N/A N/A

Roll-AwayChutes Yes Yes Yes N/A N/A

OPTIONAL EQUIPMENT (Portable Plants only)

Landing Gear No Yes Yes Yes Yes

HydraulicRun-On Jacks No Yes Yes Yes Yes

Gas/Hyd.or Elec./Hyd. No Yes Yes Yes YesPower Pk.

Hyd. ScreenAdjust (Incline No Yes Yes N/A N/AScreens only)

Swing-AwayChutes No Yes Yes Yes Yes

CrossConveyors No Yes Yes Yes Yes

RemoteGrease Yes Yes Yes Yes Yes

FlareMounting in N/A N/A Yes N/A YesKing Pin Area

Hinged/Folding Flares N/A N/A Yes N/A Yes

NOTES: Model #1814, #1822 and #1830 available in both portable and skid mounted configurations. Additionaloptions exist, consult factory for further details.Skid mounted plants can be configured to include a number ofdifferent screen and screw combinations (consult factory for details).For further capacity or specificationinformation on KPI/JCI screens, fine material washers and blademills, see the corresponding sections of thisbook relating to those pieces of equipment.

Page 120: Facts Figures Book

SCREENING THEORY

120

Screening is defined as a mechanical process whichaccomplishes a separation of particles on the basis ofsize. Particles are presented to a multitude of aper-tures in a screening surface and rejected if larger thanthe opening, or accepted and passed through ifsmaller. The material requiring separation, the feed, isdelivered to one end of the screening surface. Assum-ing that the openings in the screening media are all thesame size, movement of the material across the sur-face will produce two products. The material rejectedby 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, itcould come into contact with the solid wire or plate thatmakes up the screen media, or pass completelythrough the open hole. If the size of the particle is rel-atively small when compared to the openings, there isa high degree of probability that it will pass through oneof them before it reaches the end of the screen. Con-versely, when the particle is relatively large, or close tothe same size as the opening, there is a high degree ofprobability that it will pass over the entire screen andbe rejected to the overs. If the movement of the parti-cle is very rapid, it might bounce from wire to wire andnever reach an aperture for sizing. The velocity of theparticle, the incline of the screen, and the thickness ofthe wire all tend to reduce the effective dimensions ofthe openings and make accurate sizing more difficult.It becomes apparent that this simplified screen wouldperform much better if the following conditions pre-vailed:

1. Each particle is delivered individually to an aper-ture.

2. The particle arrives at the opening with zero forwardvelocity.

3. The particle traveled normal to the screen surface.4. The smallest dimension of the particle was cen-tered on the opening.

5. Screening surface has little or no thickness.

Page 121: Facts Figures Book

As material flows over a vibrating screening surface, ittends to develop fluid-like characteristics. The largerparticles rise to the top while the smaller particles siftthrough the voids and find their way to the bottom ofthe material bed. This phenomenon of differentiation iscalled stratification. Without stratification of the mater-ial, there would be no opportunity for the smallparticles to get to the bottom of the material bed andpass through the screen apertures causing separationof material by size.

After the material has been stratified to allow the pas-sage of throughs, the apertures are then blocked withoversize particles that were above the fines in thematerial bed before passage of more fines can occur,the bed must be restratified so the fines are again atthe bottom of the bed and available for passage. Thusthe process must be repeated successively until allfines are passed.

Potential occurrences that can prevent successfulscreening include:1. The arrival of several particles at an aperture, withthe result that none succeed in passing eventhough all are undersize.

2. Oversize particles plugging the openings so thatundersize cannot pass though.

3. Undersize particles blinding the apertures by stick-ing to the screening media which reduces theopening thus preventing passage of undersize par-ticles.

4. Oblique impact of near-size particles bouncing offthe sides of the aperture reducing efficiency.

There are two basic styles of vibrating gradationscreens manufactured to perform the material sepa-ration process. In simple terms they are: inclinedscreens and horizontal screens. Within these twobroad definitions are many different variations whichaffect the screening action and mounting systems.

INCLINE SCREENS are most commonly built with sin-gle eccentric shafts that create a circular motion. Dualshaft incline screens may be considered for heavier

121

Page 122: Facts Figures Book

duty applications. Incline screens utilize gravity as wellas the circular eccentric motion to perform the screen-ing operation. Depending upon application, inclinescreens run at angles of 10 degrees to 45 degrees.The high frequency screen typically runs very steepwhen screening at very fine openings. A primary fea-ture of the incline screen is it’s relatively low cost. Itmay also have a lower operating cost by using lesshorsepower and having fewer shafts and bearing.

FACTS ABOUT INCLINE SCREENS:1. Incline Screens have an operating angle of typically10-35 degrees.

2. Produce a higher material travel speed and a thin-ner bed depth than a flat screen, reducing thepotential for material spill-over from volumetricsurges.

3. Size for size, incline screens are more economicalin terms of capital expenditure and power con-sumption than a flat screen, and requires fewershaft assemblies and parts to maintain and replace.

4. The increased profile height provides more acces-sibility for maintenance, screen media changes,etc.

5. Circular stroke pattern produces fewer “G”‘s thanflat screen, more of a “tumbling” motion. The mate-rial has a tendency to pick up velocity as it movesdown the deck.

6. Can be configured to retain material on the deckslonger by rotating the screen’s direction, essentiallythrowing the material backwards.

BASED ON THIS DATA, AN INCLINED SCREENIS RECOMMENDED WHEN THE FOLLOWINGCONDITIONS EXIST:

• The producer has a relatively consistent feed vol-ume and gradation to the screen.

• The desired results can be achieved with the strokepattern being produced by a single or dual shaftassembly.

• The material is relatively dry (in dry applications)and does not plug the opening.

• All of the above are true and the producer does notrequire a low profile height.

122

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• Large volumetric surges of material that couldpotentially spill over the rear and sides of flatscreens are frequent.

• A replacement screen is required to fit within exist-ing or fixed screen towers/structures.

• The economics of capital expenditure and mainte-nance are top priority.

HORIZONTAL SCREENS are utilized as a low heightaggressive action screening device. Horizontalscreens are built with dual shaft (creating a straight lineaction at approximately 45 degrees to the horizontal)or triple shaft (creating an oval action with adjustablestroke angle typically between 30 and 60 degrees fromhorizontal). A primary feature of the horizontal screenis its aggressive action in applications where blindingor pegging 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 suitabil-ity on portable plants.

3. Generates more “G” forces required to dislodgeparticles that might potentially blind incline screens.

4. Produces an oval stroke pattern that can beadjusted to suit the application for increased flexi-bility through manipulating stroke length and timingangle.

5. Triple shaft design distributes the load over a largerarea and utilizes smaller bearings that can runfaster and provide a longer operating life.

6. Produces a consistent material travel speed alongthe entire length of the deck. The screen can alsobe configured to enable a slower travel speed thanincline screens for higher efficiency.

7. The relationship of the trajectory to the screeningmedia is at a true right angle, where incline screensessentially reduce the amount of open area. Inclinescreen operators often compensate for this byinstalling cloth with slightly larger openings than thedesired top size.

BASED ON THIS DATA, A HORIZONTAL SCREENIS RECOMMENDED WHEN THE FOLLOWINGCONDITIONS EXIST:

123

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• The producerrequires portabilityto move betweenvarious sites or alower profile heightis required.

• The incoming feedgradation is incon-sistent.

• When screeningefficiency/reducedcarryover is a prior-ity.

• The screen is to beused in more thanone application.

• A slow, consistentmaterial travelspeed is requiredon any or all of thedecks.

• The material has atendency to plug or blind the screen cloth.

The variations in the stroke patterns of incline and hor-izontal screens are illustrated in Figure 1.

SCREENING REVELATIONSIn 2001, performed a side-by-side test between flatand incline screens in an effort to better understandthe benefits and limitations of both designs. This datahas led to the development of the new COMBO screendesign, which was also tested and compared. Listedbelow is a general recap of the observations that weremade:

MULTI-SLOPE “COMBO” SCREENThe Combo screens utilize both inclined panels andhorizontal panels/bottom deck: 1. Inclined panel sections increases material travelspeed, thus producing thinner bed depths enablingfines to be introduced to the horizontal bottom deckfaster, which increases the bottom deck screeningcapacity, or bottom deck factor used in the VSMAscreen calculation.

124

Figure 1

Page 125: Facts Figures Book

125

2. Increased travel speed produced by incline sec-tions reduces potential for material spillover causedby volumetric surges.

3. Horizontal panels (on upper decks) and flat bottomdeck reduces travel speed and provides highscreening efficiency and reduced carryover, similarto a flat screen;

4. Only multi-slope design that utilizes a triple shaftassembly producing oval screening motion with theability to adjust stroke length, stoke angle, and RPMspeed to best suit the conditions of the application.

5. Hybrid punch-plate in feed area provides an addi-tional 10% of screening area, thereby removing a %of fines before being introduced to the actual deck.

BASED ON THIS DATA, A COMBO SCREEN ISRECOMMENDED WHEN THE FOLLOWING CONDI-TIONS EXIST:• When a high % of fines exists in the feed materialthat must be separated efficiently.

• When increased screen capacity is required withinthe same structure of “footprint.”

• When an incline screen cannot produce the desiredscreening efficiency of separation found on hori-zontal screens.

• To reduce material “spillover” caused by volumetricsurges of feed coupled with a slower travel speed ofa flat screen.

• When a single “dual purpose” screen is required toseparate both coarse and fine particles.

• When an incline screen is preferred, but cannot beinstalled due to height restrictions or limitations.

Page 126: Facts Figures Book

126

NO

TE:T

he abo

ve are

gene

ral s

creening

guidelines only. App

lication

and material c

haracteristic

swill vary each

ope

ratin

gpa

rameter to

ach

ieve

maxim

um screening

effic

ienc

y.

SMAL

L ROCK

(0 - 3/16

")BIG ROCK

(+ 24")

SMAL

L OPE

NIN

G (-

8 MES

H)

LARGE OPE

NIN

G (+

7")

HIG

H SPE

ED (+

160

0 RPM

)SL

OW SPE

ED (-

650

RPM

)

SMAL

L ST

OKE

(- 1

/32")

LARGE ST

ROKE

(+ 3/4")

MORE SL

OPE

(+ 45°

)LE

SS SLO

PE (0

- 10

°)

STEE

PER TIM

ING ANGLE

FLAT

TER TIM

ING ANGLE

(more vertical)

(more ho

rizon

tal)

INCL

INE

SCR

EEN

HO

RIZ

ON

TAL

SCR

EEN

Page 127: Facts Figures Book

127

MAX

IMU

MM

AXIM

UM

MAX

IMU

MFI

NE

STAN

DAR

DLI

GH

TM

EDIU

MH

EAVY

MAT

ERIA

LO

PEN

ING

SPEE

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MO

DEL

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SCAL

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ALPI

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SCAL

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ZE (I

N. )

aSI

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N.)

RPM

b(I

NCH

ES)

(DEG

REE

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ON

OM

Y

SCRE

ENS

“SI” In

clined

(single sh

aft)

XX

X8

480

0-11

503/8b

15-25

$$

“DI” In

clined

(dua

l sha

ft)X

XX

84

750-12

001/2b

15-25

$$

“FS”

Flat

Finish

ing

Screen

XX

82

875-10

751/2

0$$

“LP”

Flat

Stan

dard

Screen

XX

X10

5f67

5-87

53/4g

0$$

“CS”

Com

boSc

reen

XX

XX

105f

675-87

53/4g

multip

le$$

$“M

S” Flat

Med

ium

2 on

top

Scalpe

rX

XX

145

675-87

53/4

0 on

bottom

$$“H

S” Flat

Heavy

2 on

top

Scalpe

rX

XX

186

575-77

57/8

0 on

bottom

$$“Q

S” Qua

rry

Scalpe

rX

XX

36grizzly ba

r80

07/16

12$$

$$

a- c

ontrolled feed

drop he

ight re

quire

d, <24

" drop for m

aterial s

ize to 12", <

18" d

rop for m

aterial s

ize to 36"

b- s

lower spe

ed m

ust b

e us

ed w

ith m

axim

um strok

e, strok

e mus

t be less w

ith highe

r spe

eds c

- griz

zly ba

r ope

ning

can

be w

ider dep

ende

nt on ba

r design d

- 8x2

0 screen

ope

rates at 15 de

grees e

- single sh

aft w

ith 4 bearin

gs, fixed

strok

e f

- 5" m

ax ope

ning

on 5x

14, 5

x16, 6x1

6 screen

s; 4" m

ax ope

ning

on 6x

20, 7

x20, 8x2

0 g

- maxim

um strok

eis 5/8" to 3/4" dep

ending

on screen

spe

ed

SCR

EEN

MAT

RIX

Page 128: Facts Figures Book

128

MAX

IMU

MM

AXIM

UM

MAX

IMU

MFI

NE

STAN

DAR

DLI

GH

TM

EDIU

MH

EAVY

MAT

ERIA

LO

PEN

ING

SPEE

DST

RO

KESL

OPE

MO

DEL

SCR

EEN

ING

SCR

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ING

SCAL

PIN

GSC

ALPI

NG

SCAL

PIN

GSI

ZE (I

N. )

aSI

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b(I

NCH

ES)

(DEG

REE

S)EC

ON

OM

Y

KOLB

ERG

SCR

EEN

S71

Stand

ard

Inclined

XX

52.5

1100

-150

01/4

10-15

$72

Desan

der

Inclined

XX

52.5

1100

-130

03/16

25-35

$72

Griz

zly

Inclined

X10

3c10

00-120

05/16

10-15

$

PIO

NEE

RSC

REE

NS

High

Inclined

XX

63

950-10

503/16

18-22

$$Stan

dard

Inclined

XX

X12

485

0-95

03/8

10d

$$Mesab

iStan

dard

Duty

XX

X24

6c95

0-10

003/8e

10-12

$$$

Mesab

iHeavy

Duty

XX

X36

7c90

03/8e

10-15

$$$

SCR

EEN

MAT

RIX

a- c

ontrolled feed

drop he

ight re

quire

d, <24

" drop for m

aterial s

ize to 12", <

18" d

rop for m

aterial s

ize to 36"

b- s

lower spe

ed m

ust b

e us

ed w

ith m

axim

um strok

e, strok

e mus

t be less w

ith highe

r spe

eds c

- griz

zly ba

r ope

ning

can

be w

ider dep

ende

nt on ba

r design d

- 8x2

0 screen

ope

rates at 15 de

grees e

- single sh

aft w

ith 4 bearin

gs, fixed

strok

e f

- 5" m

ax ope

ning

on 5x

14, 5

x16, 6x1

6 screen

s; 4" m

ax ope

ning

on 6x

20, 7

x20, 8x2

0 g

- maxim

um strok

eis 5/8" to 3/4" dep

ending

on screen

spe

ed

Page 129: Facts Figures Book

Series 70: All series 70 screens are two bearinginclined screens and include base frame with C springsuspension and electric motor drives. These screensare a medium-light duty screen and typically are usedto size material down to #4 mesh and up to 3" maxi-mum. They are available in a range of sizes from 2' x4' to 5' x 12'.

Series 71 is a “Conventional Screen” and is availablein single, double or triple deck configurations. Eachdeck has side tensioned cloth. They operate at anincline of approximately 15°.

129

SINGLE DECKModel Size Speed (RPM) Motor71-1D244 24" x 4' 15-1700 2 HP71-1D366 36" x 6' 14-1600 3 HP71-1D368 36" x 8' 14-1600 3 HP71-1D486 48" x 6' 14-1600 3 HP71-1D488 48" x 8' 13-1500 5 HP71-1D4810 48" x 10' 13-1500 5 HP71-1D4812 48" x 10' 13-1500 7-1/2 HP71-1D6010 60" x 10' 13-1500 5 HP71-1D6012 60" x 12' 13-1500 7-1/2 HP71-1D6014 60" x 14' 11-1300 10 HP

DOUBLE DECKModel Size Speed (RPM) Motor71-2D366 36" x 6' 14-1600 3 HP71-2D486 48" x 6' 13-1500 5 HP71-2D488 48" x 8' 13-1500 7-1/2 HP

INCLINE SCREENS

Page 130: Facts Figures Book

130

71-2D4810 48" x 10' 11-1300 10 HP71-2D4812 48" x 12' 11-1300 10 HP71-2D6010 60" x 10' 11-1300 10 HP71-2D6012 60" x 12' 11-1300 10 HP71-2D6014 60" x 14' 11-1300 10 HP

TRIPLE DECKModel Size Speed (RPM) Motor71-3D366 36" x 6' 13-1500 5 HP71-3D488 48" x 8' 11-1300 10 HP71-3D4810 48" x 10' 11-1300 10 HP

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

DOUBLE DECKModel Size Speed Motor72-2D488 48" x 8' 11-1300 7-1/2 HP72-2D4810 48" x 10' 11-1300 10 HP72-2D4812 48" x 12' 11-1300 10 HP72-2D6010 60" x 10' 11-1300 10 HP72-2D6012 60" x 12' 11-1300 10 HP

Series 77 is a “Vibrating Grizzly” and is available insingle or double deck configurations. Grizzly Bars areavailable in fixed or adjustable configurations. Singledeck configurations include grizzly bars only. Doubledeck configurations include grizzly bars on the topdeck and side tensioned screen cloth on the bottomdeck. Coil impact springs are mounted inside of the Csprings. They operate at an incline angle of approxi-mately 15°.

SINGLE DECKModel Size Speed Motor77-1DG-(F or A) 366 36" x 6' 13-1500 7-1/2 HP77-1DG-(F or A) 488 48" x 8' 11-1300 10 HP

DOUBLE DECKModel Size Speed Motor77-2DG-(F or A) 488 48" x 8' 11-1300 15 HP77-2DG-(F or A) 4810 48" x 10' 11-1300 15 HP

Note: F = Fixed grizzly barsA = Adjustable grizzly bars

Page 131: Facts Figures Book

131

22° INCLINE SCREENS

DOUBLE DECKModel Size Speed (RPM) Motor2D4812 48" x 12' 950-1050 7-1/2 HP2D6012 60" x 12' 950-1050 10 HP2D6014 60" x 14' 950-1050 15 HP2D6016 60" x 16' 950-1050 15 HP2D7216 72" x 16' 950-1050 20 HP

TRIPLE DECKModel Size Speed (RPM) Motor3D4812 48" x 12' 950-1050 10 HP3D6012 60" x 12' 950-1050 15 HP3D6014 60" x 14' 950-1050 20 HP3D6016 60" x 16' 950-1050 20 HP3D7216 72" x 16' 950-1050 30 HP

These economy screens run at lower speeds andutilize gravity to assist the motion created by theeccentric shaft for moving material. The single shaft, 2bearing design is recommended for light to standardduty applications.

Page 132: Facts Figures Book

132

10° INCLINE SCREENS

DOUBLE DECKModel Size Speed (RPM) Motor2D3610 36" x 10' 850-950 7-1/2 HP2D4810 48" x 10' 850-950 10 HP2D4812 48" x 12' 850-950 15 HP2D6012 60" x 12' 850-950 20 HP2D6014 60" x 14' 850-950 25 HP2D6016 60" x 16' 850-950 30 HP2D7216 72" x 16' 850-950 30 HP2D7220 72" x 20' 850-950 30 HP2D9620 96" x 20' 850-950 40 HP

TRIPLE DECKModel Size Speed (RPM) Motor3D3610 36" x 10' 850-950 10 HP3D4810 48" x 10' 850-950 15 HP3D4812 48" x 12' 850-950 20 HP3D6012 60" x 12' 850-950 25 HP3D6014 60" x 14' 850-950 30 HP3D6016 60" x 16' 850-950 40 HP3D7216 72" x 16' 850-950 40 HP3D7220 72" x 20' 850-950 40 HP3D9620 96" x 20' 850-950 50 HP

*

*

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

The 10 degree screen combines the economy of thesingle shaft, 2 bearing incline screens with the heavyduty, aggressive action of the horizontal screens.Perfect for portable applications and in situationswhere headroom is limited, the screen has a 3/8 inchcircular stroke and runs at an RPM around 950. Theheavy-duty pan and deck construction make it perfectfor applications ranging from standard to heavy-duty.

Page 133: Facts Figures Book

133

Incline Screens feature HD side and reinforcing plates,huck bolted construction, an adjustable operatingincline from 15-25 degrees, adjustable stroke ampli-tudes, AR lined feed boxes, and HD double-roll bronzecage spherical roller bearings.

Incline Screens are available in both single and dualshaft arrangements, two and three deck configura-tions, and are available in sizes ranging from 5x16 upto 8x20.

INCLINED SCREENS

SINGLE SHAFT INCLINED SCREENSSingle Shaft Incline Screens are well suited for sta-tionary installations, for applications where the feedgradation to the screen is constant, or when a circularstroke pattern will provide the desired results. Inclinescreens also enable a lower bed depth of material dueto an increased material travel speed. to minimizepower consumption while maximizing access for main-tenance

Screen size: 5162 & 51636162 & 61636202 & 62037202 & 72038202 & 8203

PATENT APPLIED FOR

Page 134: Facts Figures Book

134

In addition to the benefits described of the single shaftincline designs, Dual Shaft Incline Screens will provideincreased bearing life as compared to a single shaftarrangement, due to the load being distributed overadditional bearing surface. In some cases, dual shaftscreens will also provide the benefit of a more aggres-sive screen action in applications where the feed endof the screen becomes “top heavy” with a high volumeof material.

DUAL SHAFT INCLINED SCREENS

Screen size: 6162 & 61636202 & 62037202 & 72038202 & 8203

PATENT APPLIED FOR

Page 135: Facts Figures Book

135

SCALPING SCREENS

DOUBLE DECKModel Size Speed (RPM) Motor2D4810 48" x 10' 950-1000 20 HP2D4812 48" x 12' 950-1000 25 HP2D6012 60" x 12' 950-1000 30 HP2D6014 60" x 14' 950-1000 40 HP2D7216 72" x 16' 950-1000 50 HP

HEAVY DUTYModel Size Speed (RPM) Motor2D488 48" x 8' 900 30 HP2D6014 60" x 14' 900 40 HP2D7214 72" x 14' 900 50 HP

MESABI (PIONEER) TYPE SINGLE SHAFT4-BEARING STANDARD DUTY

Page 136: Facts Figures Book

Horizontal Screens are of a triple shaft design that pro-vides a true oval vibrating motion, and feature ahuck-bolted basket assembly, fully contained lubrica-tion system, and rubber springs to reduce basketstress. Their low profile height makes them ideal forportability, and their adjustment capabilities of speed,stroke length, and stroke angle enable them to be wellsuited for both fine and coarse screening applications.Horizontal Screens can be retrofitted with either wirecloth or urethane panels, and can be easily convertedto wet screen applications.

HorizontalScreens areavailable inseveral configu-rations in sizesranging from5x14 up to8x20 in bothtwo and threedeck designs.

136

HORIZONTAL VIBRATING SCREENS

PATENT APPLIED FOR

FINISHING SCREENSThe Finishing Screen maximizes screening efficiencyand productivity in fine separation applications by uti-lizing a reduced stroke and a higher frequency thatprovides an optimal sifting action.Adjustable stroke length (Amplitude) . . . . . . . . . . . . . min 3⁄8" to max 1⁄2"

(Stroke reduced by removing weight plugs.)Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 875-1075 rpmMaximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 8"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . All model screens = 2"Screen size: 5142-32FS & 5143-32FS

5162-32FS & 5163-32FS6162-32FS & 6163-32FS6202-32FS & 6203-32FS7202-38FS & 7203-38FS8202-38FS & 8203-38FS

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137

STANDARD SCREENSThe Standard Series are best suited for the widestarray of applications ranging from fine to coarse mate-rial separation applications.

Adjustable stroke length (Amplitude) . . . . . . . . . . . . . min 5⁄8" to max 3⁄4"(Stroke reduced by removing weight plugs.)

Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 675-875 rpmMaximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 10"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . 514, 516 & 616 = 5"

620, 720 & 820 = 4"Screen size: 5142-32LP & 5143-32LP

5162-32LP & 5163-32LP6162-32LP & 6163-32LP6202-32 & 6203-32 (2.5°)6202-32LP & 6203-32LP7202-38LP & 7203-38LP8202-38LP & 8203-38LP

PATENT APPLIED FOR

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138

Adjustable stroke length (Amplitude) . . . . . . . . . . . . . min 9⁄16" to max 3⁄4"Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 675-875 rpmMaximum feed size* . . . . . . . . . . . . . . . . . . . . . . . . . . 14"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . All model screens = 5"Screen size: 5142-32MS & 5143-32MS

5162-32MS & 5163-32MS6162-32MS & 6163-32MS6202-32MS & 6203-32MS7202-38MS & 7203-38MS8202-38MS & 8203-38MS

MEDIUM SCALPER SCREENSThe Medium Scalper Screen is an excellent machinefor coarse screening and light duty scalping applica-tions, by implementing a slightly lower frequency andmore aggressive stroke length as compared to thestandard series. Medium Scalper Screens also featurea heavier duty construction for up to 14" feed.

PATENT APPLIED FOR

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139

HEAVY SCALPER SCREENSThe Heavy Scalper Two-Deck Screens are designedfor heavy duty scalping applications, by implementingthe lowest frequency and most aggressive strokelength in the family of Horizontal Screens. Heavyscalper screens also feature the heaviest duty con-struction that can accept up to 18" feed sizes.

EXTRA-HEAVY SCALPER SCREENSThe Extra-Heavy Scalper Screens are also availablewith a stepped grizzly bar top deck designed to handleup to 24" feed size.

Screen size: 5142-32HSHD5162-32HSHD6162-38HSHD6202-38HSHD7202-38HSHD8202-38HSHD

Adjustable stroke length* (Amplitude) . . . . . . . . . . . . min 3⁄4" to max 7⁄8"(Stroke reduced by removing weight plugs.)

Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range* . . . . . . . . . . . . . . . . . . . . . . . 575-775 rpmMaximum feed size* . . . . . . . . . . . . . . . . . . . . . . . . . . 18"Maximum top deck opening* . . . . . . . . . . . . . . . . . . . All model screens = 6"Screen size: 5142-32HS & 5143-32HS

5162-32HS & 5163-32HS6162-38HS & 6163-38HS6202-38HS & 6203-38HS7202-38HS8202-38HS

PATENT APPLIED FOR

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140

Size of Plug RPM of TimingMaterial Configuration Screen AngleCoarse 3 Plugs Each Wheel Very Slow11⁄4" Plus 3⁄4" Approximately 740 RPM 45° - 55°

SlowMedium 2 Plugs Each Wheel 3⁄4" to 11⁄4" 40° - 50°3⁄4" - 11⁄4" 11/16" Approximately 785 RPM

FastFine 1 Plug Each Wheel 3⁄4" to 11⁄4" 35° - 45°

3⁄4" - 11⁄4" 5⁄8" Approximately 830 RPMNo Plugs Each Wheel

Extra Fine 9⁄16" Approximately Very Fast 30° - 40°3⁄8" Minus Minimum Stroke 875 RPM

GUIDELINES FOR STROKE ADJUSTMENTS

Figure 2

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141

COMBO® Screens combine the advantages of both aninclined screen and a horizontal screen. The screen isequipped with incline panel sections that begin with a20-degree section, flatten to a 10 degree section, andthe remaining deck area is at zero degrees.

By installing sloped sections at the feed end, materialbed depth is reduced since gravity will increase thetravel speed of the material. This reduced bed depthminimizes spillover, and enables fine particles to “strat-ify” through the coarser particles and onto thescreening surface much faster, where it can then findmore opportunities to be passed through screen open-ings. This design also enables fines to be introduced tothe bottom deck faster, which increases the bottomdeck screening capacity, or bottom deck factor used inthe VSMA screen calculation.

They have also designed a punch plate section intothe feed plate itself, thereby increasing the totalscreening area by an additional 10%. This punch platewill remove a high percentage of fine particles beforethey are even introduced to the actual screen deck,thereby increasing production volumes.

The coarse “near” size and “over” size particles thatare not initially separated on the middle and top decksgradually slow down as the deck panels flatten out tothe horizontal section towards the discharge end of thescreen. This material’s reduced travel speed, com-bined with the optimum angle of trajectory inrelationship to the screen opening, provides a highscreening efficiency that oval motion horizontalscreens have built their reputation on.

MULTI-ANGLE SCREENS

PATENT APPLIED FOR

Page 142: Facts Figures Book

The COMBO Screen is also the only multi-slopedesign that features a triple shaft design. This designprovides an optimal oval screening motion that hasproven effective over decades of success in the com-pany’s traditional flat screen design. In addition to thefeatures of the COMBO design, producers will alsobenefit by having the ability to adjust stroke length,stroke angle, and RPM speed to best suit the condi-tions of the application.

The end result is a machine that:1) Provides increased feed production by as much as20% over standard flat or incline screens;

2) Maintains or improves the screening efficiency ofseparation found on horizontal screens;

3) Reduces material spillover at the feed end fromhigh 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 horizontalscreens, the COMBO design will be an ideal screen fora variety of both scalping and product sizing applica-tions. The design is especially well suited for acceptinglarge volumetric feed ‘surges’, deposits containing ahigh percentage of fines that must be removed, instal-lations where screening capacity must be increasedwithin the same structural or mounting ‘footprint’, or inclosed circuit with crushers.

COMBO Screens are available in both a standard dutyand finishing duty three deck configurations and arecurrently available in 6x20, 7x20 and 8x20 sizes.COMBO Screens feature huck-bolt construction,incline deck panels that slope from 20 to zero degrees,adjustable stroke amplitudes, a hinged tailgate rearsection for maintenance access, and a perforated feedbox for additional screening area. COMBO Screenscan be installed with either standard wire cloth or ure-thane/rubber deck panels.

142

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143

Adjustable stroke length (Amplitude) . . . . . . . . . . . . . min 5⁄8" to max 3⁄4"(Stroke reduced by removing weight plugs.)

Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 675-875 rpmMaximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 10"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . 4"Screen size: 6202-32CS & 6203-32CS

7202-38CS & 7203-38CS8202-38CS & 8203-38CS

PATENT APPLIED FOR

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144

VSMA FACTORS FOR CALCULATING SCREEN AREAFormula: Screening Area = U

A x B x C x D x E x F x G x H x J*Basic Operating Conditions

Feed to screening deck contains 25% oversize and 40% halfsizeFeed is granular free-flowing materialMaterial 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%

FACTOR “A”Surface % STPHSquare Open PassingOpening Area A Sq. Ft.

4" 75% 7.69

31⁄2" 77% 7.03

3" 74% 6.17

23⁄4" 74% 5.85

21⁄2" 72% 5.52

2" 71% 4.90

13⁄4" 68% 4.51

11⁄2" 69% 4.20

11⁄4" 66% 3.89

1" 64% 3.567⁄8" 63% 3.383⁄4" 61% 3.085⁄8" 59% 2.821⁄2" 54% 2.473⁄8" 51% 2.081⁄4" 46% 1.603⁄16" 45% 1.271⁄8" 40% .953⁄32" 45% .761⁄16" 37% .581⁄32" 41% .39

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

% Oversize 5 10 15 20 25 30 35Factor B 1.21 1.13 1.08 1.02 1.00 .96 .92

% Oversize 40 45 50 55 60 65 70Factor B .88 .84 .79 .75 .70 .66 .62

% Oversize 75 80 85 90 95Factor B .58 .53 .50 .46 .33

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

% Halfsize 0 5 10 15 20 25 30Factor C .40 .45 .50 .55 .60 .70 .80

% Halfsize 35 40 45 50 55 60 65Factor C .90 1.00 1.10 1.20 1.30 1.40 1.55

% Halfsize 70 75 80 85 90Factor C 1.70 1.85 2.00 2.20 2.40

FACTOR “E”(Wet Screening)

Opening 1⁄32" 1⁄16" 1⁄8" 3⁄16" 1⁄4" 3⁄8" 1⁄2" 3⁄4" 1"Factor E 1.00 1.25 2.00 2.50 2.00 1.75 1.40 1.30 1.25

FACTOR “F”(Material Weight)

Lbs./cu.ft. 150 125 100 90 80 75 70 60 50 30Factor F 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

FACTOR “D”(Deck Location)

Deck Top Second ThirdFactor D 1.00 .90 .80

FACTOR “H”(Shape of Surface

Opening)

Square . . . . . . . . . . 1.00Short Slot (3 to 4 times Width) . . . . 1.15

Long Slot (More than 4 Times Width) . 1.20

FACTOR “J”(Efficiency)

95% . . . . . . . . . . . . 1.0090% . . . . . . . . . . . . 1.1585% . . . . . . . . . . . . 1.3580% . . . . . . . . . . . . 1.5075% . . . . . . . . . . . . 1.7070% . . . . . . . . . . . . 1.90

**Furnished by VSMA U = STPH Passing Specified Aperture

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145

SPRAY PIPE DESIGNAMOUNT 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 PipeDual Flat Spray PatternStandard Orifice Size 1/4"

Splash Spray PipeSingle Flat Splash Pattern3/16" Diameter Holes on 2" Centers

8203-38LP 6 6 5 17 425 3017 3655 42508202-38LP 6 - 5 11 275 1952 2365 27507203-38LP 6 6 5 17 374 2655 3216 37407202-38LP 6 - 5 11 242 1718 2081 24206203-32LP 6 6 5 17 323 2293 2778 32306202-32LP 6 - 5 11 209 1484 1797 20906163-32LP 5 5 4 14 266 1889 2288 26606162-32LP 5 - 4 9 171 1214 1471 17105163-32LP 5 5 4 14 210 1491 1806 21005162-32LP 5 - 4 9 135 959 1161 13505143-32LP 4 4 4 12 180 1278 1548 18005142-32LP 4 - 4 8 120 852 1032 1200

TOTAL TOTAL GAL. PER GAL. PER GAL. PERPIPES/DECK PIPES NOZZLES SCREEN SCREEN SCREEN

SCREEN PER PER AT 20 PSI AT 30 PSI AT 40 PSIMODEL TOP CTR BT SCREEN SCREEN 1⁄4" ORIFICE 1⁄4" ORIFICE 1⁄4" ORIFICE

STANDARD NOZZLE ORIFICE SIZE 1⁄4"20 PSI at Nozzle capacity is 7.1 gallons per minute30 PSI at Nozzle capacity is 8.6 gallons perminute40 PSI at Nozzle capacity is 10 gallons per minute

8' Spray Pipe has 25 Nozzles per pipe7' Spray Pipe has 22 Nozzles per pipe6' Spray Pipe has 19 Nozzles per pipe5' Spray Pipe has 15 Nozzles per pipe

SPLASH SPRAY PIPES

Approximately the same capacity as Nozzle Spray Pipes Shown above.

Page 146: Facts Figures Book

CONVEYORS—INTRODUCTIONBelt conveyors are designed to carry material via theshortest distance between the loading and unloadingpoints. When required, belt conveyors can operatecontinuously, without loss of time, and are capable ofhandling tonnages of bulk materials that would bemore costly and often impractical to transport by othermeans. This often avoids confusion, delays, and safetyhazards of rail and motor traffic in plants and othercongested areas.

Choosing the right conveyor starts with looking at thefive basic considerations: material characteristics, con-veyor length and/or discharge height, TPH feed,conveyor width, and HP requirements.

1. Material Characteristicsa. Variables include: Particle Shape, Particle Size,Moisture, Angle of Repose, Lump Size & % Fines andWeight. Characteristics normally used as a rule ofthumb include: 100 lbs. per cubic foot density, 37degree angle of repose and less than 25% of a max. 3"lump.

146

° Angle ° AngleMaterial Incline % Grade Material Incline % GradeAlumina . . . . . . . . . . . . . . . 10-12 17.6-21.2 Gypsum, 1/2" Screening . . . 21 38.3Ashes, Coal, Dry, 1/2" Gypsum, 1-1/2" to 3"and Under . . . . . . . . . . . . 20-25 36.4-46.6 Lumps . . . . . . . . . . . . . . . . 15 26.8

Ashes, Coal, Wet, 1/2" Earth—Loose and Dry. . . . . 20 36.4and Under . . . . . . . . . . . . 23-27 42.4-50.4 Lime, Ground, 1/8"

Ashes, Fly. . . . . . . . . . . . . . 20-22 36.4-40.4 and Under . . . . . . . . . . . . . 23 42.4Bauxite, Ground, Dry . . . . . 20 36.4 Lime, Pebble . . . . . . . . . . . . 17 30.6Bauxite, Mine Run . . . . . . . 17 30.6 Limestone, Crushed . . . . . . 18 32.5Bauxite, Crushed 3" Limestone, Dust . . . . . . . . . 20 36.4and Under . . . . . . . . . . . . 20 36.4 Oil Shale . . . . . . . . . . . . . . . 18 32.5

Borax, Fine . . . . . . . . . . . . . 20-25 36.4-46.6 Ores—Hard—PrimaryCement, Portland . . . . . . . . 23 42.4 Crushed. . . . . . . . . . . . . . . 17 30.6Charcoal . . . . . . . . . . . . . . . 20-25 36.4-46.6 Ores—Hard—SmallCinders, Blast Furnace . . . . 18-20 32.5-36.4 Crushed Sizes . . . . . . . . . . 20 36.4Cinders, Coal . . . . . . . . . . . 20 36.4 Ores—Soft—NoCoal Crushing Required . . . . . . 20 36.4Bituminous, Run of Mine . 18 32.4 Phosphate Triple Super,. . . . Bituminous, Fines Only . . 20 36.4 Ground Fertilizer . . . . . . . . 30 57.7Bituminous, Lump Only . . 16 28.6 Phosphate Rock,Anthracite, Run of Mine . . 16 28.6 Broken, Dry . . . . . . . . . . . . 12-15 21.2-26.8Anthracite, Fines . . . . . . . 20 36.4 Phosphate Rock, Pulverized 25 46.6Anthracite, Lump Only . . . 16 28.6 Rock, Primary Crushed . . . . 17 30.6Anthracite, Briquettes. . . . 12 21.3 Rock, Small Crushed Sizes . 20 36.4

Coke—Run of Oven . . . . . . 18 32.4 Sand—Damp. . . . . . . . . . . . 20 36.4Coke, Breeze . . . . . . . . . . . 20 36.4 Sand—Dry . . . . . . . . . . . . . 15 26.8Concrete—Normal . . . . . . . 15 26.8 Salt . . . . . . . . . . . . . . . . . . . 20 36.4Concrete—Wet Soda Ash (Trona) . . . . . . . . 17 30.6(6" Slump) . . . . . . . . . . . . 12 21.3 Slate, Dust. . . . . . . . . . . . . . 20 36.4

Chips—Wood . . . . . . . . . . 27 50.9 Slate, Crushed, 1/2"Cullet . . . . . . . . . . . . . . . . . 20 36.4 and Under . . . . . . . . . . . . . 15 26.8Dolomite, Lumpy . . . . . . . . 22 40.4 Sulphate, Powder . . . . . . . . 21 38.3Grains—Whole . . . . . . . . . 15 26.8 Sulphate, Crushed—1/2" . . . Gravel—Washed . . . . . . . . 15 26.8 and Under . . . . . . . . . . . . . 20 36.4Gravel and Sand. . . . . . . . . 20 36.4 Sulphate, 3" and Under . . . . 18 32.5Gravel and Sand Taconite—Pellets . . . . . . . . 13-15 23.1-26.8Saturated . . . . . . . . . . . . . 12 21.3 Tar Sands . . . . . . . . . . . . . . 18 32.5

Gypsum, Dust Aerated . . . . 23 42.4

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

RECOMMENDED MAXIMUM ALLOWABLE INCLINEFOR BULK MATERIALS

Page 147: Facts Figures Book

b. Material characteristics can affect other elements ofconveyor selection.

• Heavier material or large lumps may require moreHP, heavier belt, closer idler spacing and impactidlers at feed points.

• Abrasiveness may require wear liners or specialrubber compositions.

• Moisture may require steeper hopper sides, widerbelts, anti-buildup return idlers and special beltwipers.

• Dust content may require special discharge hoodsand chutes, slower belt speeds and hood covers.

• Sharp materials may require impact idlers, wear lin-ers, special belt and plate feeder.

• Lightweight materials may require wider belts andless horsepower.

c. Conveyor Belt

Conveyor belt consists of three elements: top cover,carcass, and bottom cover.

The belt carcass carries the tension forces necessaryin starting and moving the loaded belt, absorbs theimpact energy of material loading, and provides thenecessary stability for proper alignment, and load sup-port over idlers, under all operating conditions.

Because the primary function of the cover is to protectthe carcass, it must resist the wearing effects of abra-sion and gouging, which vary according to the type ofmaterial conveyed. The top cover will generally bethicker than the bottom cover because the concentra-tion of wear is usually on the top, or carrying side.

The belt is rated in terms of “maximum recommendedoperating tension” pounds per inch of width (PIW).The PIW of the fabric used in the belt is multiplied bythe number of plies in the construction of the belt todetermine the total PIW rating of the belt.

147

Page 148: Facts Figures Book

d. Idlers

Idler selection is based on the type of service, operat-ing condition, load carried, and belt speed.

148

RollFormer Diameter

Classification Series No. (Inches) Description

A4 I 4 Light DutyA5 I 5 Light DutyB4 II 4 Light DutyB5 II 5 Light DutyC4 III 4 Medium DutyC5 III 5 Medium DutyC6 IV 6 Medium DutyD5 NA 5 Medium DutyD6 NA 6 Medium DutyD7 VI 7 Heavy DutyE6 V 6 Heavy Duty

CEMA IDLER CLASSIFICATION

2. Length

Length is determined one of three ways:

a. Lift Height Required: When lift height is the deter-mining factor, as a rule of thumb, an 18 degree inclineis used, where 3 x height needed approximates theconveyor length required. Particle size, moisture andother factors affect the maximum incline angle. If thematerial tends to have a conveyable angle that is lessthan 18 degrees, a longer conveyor needs to beselected to achieve the desired lift height.

b. Distance to be conveyed

c. Stockpile Capacity Desired

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149

CONVEYOR ELEVATION CHART

HORIZONTAL DISTANCE IN FEET

CONVEYOR LENGTH IN FEET

40'

40'

50'

60'

80'

100'

120'

150'

21° 18° 15° 12° 9°

50'

60'

80'

100'

120'

150'

60'

50'

40'

30'

5'10'

20'

ELEVATION IN FEET

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150

CONVEYOR ELEVATIONConveyor Length Conveyor Angle Height (ft.)

40 12 10.340 15 12.440 18 14.440 21 16.360 12 14.560 15 17.560 18 20.560 21 23.580 12 18.680 15 22.780 18 26.780 21 30.7100 12 22.8100 15 27.9100 18 32.9100 21 37.8125 12 28.0125 15 34.4125 18 40.6125 21 46.8150 12 33.2150 15 40.8150 18 48.4150 21 55.8

LL

2'

H

Head Pulley

H=Sinθ(L)+2'

C

Page 151: Facts Figures Book

151

"D" APPROX

"H"

37.5° 37.5°

DEAD STORAGE

LIVE STORAGE

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

GROSS VOLUME = 1⁄3 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°

CONICAL STOCKPILE CAPACITY

Volume Volume Tons Tons

(100 lbs. (100 lbs.H D Cu. Yds. /cu. ft.) H D Cu. Yds. /cu. ft.)

6 16 14 19 26 68 1158 15638 21 34 46 28 73 1446 195210 26 66 89 30 78 1779 240112 31 114 154 35 91 2824 381314 36 181 244 40 104 4216 569116 42 270 364 45 117 6003 810418 47 384 519 50 130 8234 1111620 52 527 711 55 143 10960 1479522 57 701 947 60 156 14228 1920824 63 911 1229

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152

APPROXIMATE VOLUME OFCIRCULAR STOCKPILE

V3 = V1 + V2θ

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.

V2 = 1187

H = Height of Stockpile - in feetR = Radius of Arc (C Pile to C Pivot) - in feetR = cos 18° x conveyor length L

NOTE: V2 based on 37.5° angle of reposeθ = Angle of Arc - in degrees

H2R

L L

V1

2

R

VOLUME OF STOCKPILE SEGMENT FOR 1° ARC V2

V1

2

θ

Page 153: Facts Figures Book

153

V2 = Volume of Stockpile Segment for 1 degree Arc (cu. yds.)

Radius(in feet) 10 15 20 25 30 35 40 45 50 5525 2.130 2.535 2.9 6.640 3.4 7.645 3.8 8.550 4.2 9.5 16.855 4.6 10.4 18.560 5.1 11.4 20.2 31.665 5.5 12.3 21.9 34.270 5.9 13.3 23.6 36.975 6.3 14.2 25.3 39.5 56.980 6.7 15.2 27.0 42.1 60.785 7.2 16.1 28.6 44.8 64.4 87.790 7.6 17.1 30.3 47.4 68.2 92.995 8.0 18.0 32.0 50.0 72.0 98.0100 8.4 19.0 33.7 52.7 75.8 103.2 134.8105 8.8 19.9 35.4 55.3 79.6 108.4 141.5110 9.3 20.9 37.1 57.9 83.4 113.5 148.3 187.7115 9.7 21.8 38.8 60.6 87.2 118.7 155.0 196.2120 10.1 22.7 40.4 63.2 91.0 123.8 161.8 204.7 252.7125 10.5 23.7 42.1 65.8 94.8 129.0 168.5 213.2 263.3130 11.0 24.6 43.8 68.4 98.6 134.2 175.2 221.8 273.8135 11.4 25.6 45.5 71.1 102.4 139.3 182.0 230.3 284.3 344.0140 11.8 26.5 47.2 73.7 106.1 144.5 188.7 238.8 294.9 356.8145 12.2 27.5 48.9 76.3 109.9 149.6 195.5 247.4 305.4 369.5150 12.6 28.4 50.5 79.0 113.7 154.8 202.2 255.9 315.9 382.3

3. TPH Feed

See belt carrying capacity chart. As a rule of thumb, at350 fpm, 35 degree troughing idlers and 100 lbs/cu. ft.material, a 24" belt carries 300 TPH, a 30" belt carries600 TPH and a 36" belt carries 900 TPH.

Stockpile Height (H) in Feet

L H R V1 V1 V2 V2 V3 V390° 90°

stockpile stockpileFeet Feet Feed Cu. Yds. Tons Cu. Yds. Tons Cu. Yds. Tons60 20.5 57 567 766 20.2 27.3 2,385 3,22380 26.7 76 1,254 1,693 45.6 61.6 5,358 7,237100 32.9 95 2,346 3,167 86.6 116.9 10,140 13,688120 39.1 114 3,938 5,316 146.8 198.2 17,150 23,154150 48.4 142.5 7,469 10,083 281.2 379.6 32,777 44,247

Examples:

Page 154: Facts Figures Book

154

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310

345

379

414

2413

219

826

433

039

646

252

859

466

072

679

2

3021

532

243

053

764

575

286

096

710

7511

8212

90

3631

847

763

679

595

411

1312

7214

3115

9017

4919

08

4244

166

188

211

0213

2315

4317

6419

8422

0524

2526

46

4858

587

711

7014

6217

5520

4723

4026

3229

2532

1735

10

5474

811

2214

9618

7022

4426

1829

9233

6637

4041

1444

88

6093

213

9818

6423

3027

9632

6237

2841

9446

6051

2655

92

7213

6020

4027

2034

0040

8047

6054

4061

2068

0074

8081

60

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4. Conveyor Width

There are a number of factors that affect width. Theseinclude TPH feed, future considerations, lump size andthe % of fines, cross section of how the material settleson the belt, and material weight.

a. Normally, portable conveyors are set-up to run at350 feet per minute, as this is accepted as the bestspeed for the greatest number of types of material andoptimum component life. When it is desirable to run ata different speed, this will usually be a factory decisionbased on the material and the capabilities requestedby the customer. These variations are generally applic-able on engineered systems.

RECOMMENDED MAXIMUM BELT SPEEDSBelt Speeds Belt Width

Material being conveyed (fpm) (inches)

Grain or other free-flowing, nonabrasive 500 18material 700 24-30

800 36-421000 48-96

Coal, damp clay, soft ores, overburden and 400 18earth, fine-crushed stone 600 24-36

800 42-601000 72-96

Heavy, hard, sharp-edged ore, 350 18coarse-crushed stone 500 24-36

600 Over 36

Foundry sand, prepared or damp; shakeoutsand with small cores, with or without small 350 Any widthcastings (not hot enought to harm belting)

Prepared foundry sand and similar damp (ordry abrasive) materials discharged from belt 200 Any widthby rubber-edged plows

Nonabrasive Materials discharged from belt 200 Any widthby means of plows except for

wood pulp,where 300 to

400 ispreferable

Feeder belts, flat or troughed, for feedingfine, nonabrasive, or midly abrasive materials 50 to 100 Any widthfrom hoppers and bins

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b. Lump size and the % of fines can have a majoraffect on width selection. As a rule of thumb, for a 20-degree surcharge angle, with 10 percent lumps and 90percent fines, the recommended maximum lump sizeis one third of the belt width (BW/3). With all lumps andno fines, the recommended maximum lump size is onefifth of the belt width (BW/5). For a 30-degree sur-charge angle, with 10 percent lumps and 90 percentfines, the recommended maximum lump size is onesixth of the belt width (BW/6). With all lumps and nofines, the recommended maximum lump size is onetenth of the belt width (BW/10). Belts must be wideenough so any combination of lumps and fine materialdo not load the lumps too close to the edge of the belt.

c. The cross section of how the material settles on amoving belt can have a major affect on expected ton-nage for a given width conveyor.

FACTORS AFFECTING THE CROSS SECTION ARE:

• The angle of repose of a material is the angle thatthe surface of a normal, freely formed pile, makes tothe horizontal.

• The angle of surcharge of a material is the angleto the horizontal that the surface of the materialassumes while the material is at rest on a movingconveyor belt. This angle usually is 5° to 15° lessthan the angle of repose, though in some materialsit may be as much as 20° less.

• The flowability of a material, as measured by itsangle of repose and angle of surcharge, determinesthe cross-section of the material load that safelycan be carried on a belt. It also is an index of thesafe angle of incline of the belt conveyor. The flowa-bility is determined by such material characteristicsas: size and shape of the fine particles and lumps,roughness or smoothness of the surface of thematerial particles, proportion of fines and lumpspresent, and moisture content of material.

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FLOWABILITY—ANGLE OF SURCHARGE—ANGLE OF REPOSE

Very freeflowing Free flowing Average Flowing Sluggish

5° Angle of 10° Angle of 20° Angle of 25° Angle of 30° Angle ofsurcharge surcharge surcharge surcharge surcharge

0°-19° Angle 20°-29° Angle 30°-34° Angle 35°-39° Angle 40°-up Angleof repose of repose of repose of repose of repose

MATERIAL CHARACTERISTICSUniform size, Rounded, dry Irregular, granu- Typical common Irregular,very small polished particles, lar or lumpy materials such as stringy, fibrous,rounded particle, of medium weight, materials of bituminous coal, interlocking mate-either very wet or such as whole medium weight, stone, most ores, ial, such as woodvery dry, such as grain or beans. such as anthra- etc. chips, bagasse,dry silica sand, cite coal, cotton- tempered foundrycement, wet con- seed meal, clay, sand, etc.crete, etc. etc.

d. The material weight affects the volume, whichaffects the width. Most aggregate weighs between 90-110 lbs. per cubic foot. When the weight variessignificantly, it can have a dramatic effect on expectedbelt width needed to achieve a given tonnage.

5. HP Requirements

The power required to operate a belt conveyor dependson the maximum tonnage handled, the length of theconveyor, the width of the conveyor and the verticaldistance that the material is lifted. Factors X + Y + Z(from tables below) = Total HP Required at Head-shaft. The figures shown are based on averageconditions with a uniform feed and at a normal operat-ing speed. Additional factors such as pulley friction,skirtboard friction, material acceleration and auxiliarydevice frictions (mechanical feeder, tripper, etc.) mayrequire an increase in horsepower.

Drive efficiency is taken into consideration to deter-mine the motor horsepower required. This can be anadditional 10-15% above the headshaft HP. The abilityto start a loaded conveyor will also require an addi-tional HP consideration.

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Center-Center of PulleysTPH 25' 50' 75' 100' 150' 200' 250' 300' 350' 400'

100 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.3 1.4 1.5150 0.8 0.9 1.0 1.1 1.3 1.5 1.7 1.9 2.1 2.3200 1.0 1.2 1.3 1.5 1.7 2.0 2.2 2.5 2.8 3.0250 1.3 1.5 1.6 1.9 2.1 2.5 2.8 3.1 3.5 3.8300 1.5 1.8 2.0 2.3 2.6 3.0 3.3 3.8 4.2 4.5350 1.8 2.1 2.3 2.6 3.0 3.5 3.9 4.4 4.9 5.3400 2.0 2.4 2.6 3.0 3.4 4.0 4.4 5.0 5.6 6.0500 2.5 3.0 3.3 3.8 4.3 5.0 5.5 6.3 7.0 7.5600 3.0 3.6 3.9 4.5 5.1 6.0 6.6 7.5 8.4 9.0700 3.5 4.2 4.6 5.3 6.0 7.0 7.7 8.8 9.8 10.5800 4.0 4.8 5.2 6.0 6.8 8.0 8.8 10.0 11.2 12.0900 4.5 5.4 5.9 6.8 7.7 9.0 9.9 11.3 12.6 13.51000 5.0 6.0 6.5 7.5 8.5 10.0 11.0 13.0 14.0 15.0

FACTOR Z - HORSEPOWER REQUIRED TO LIFT LOAD ON BELT CONVEYOR

LiftTPH 10' 20' 30' 40' 50' 60' 70' 80' 90' 100'

100 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0150 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12.0 13.5 15.0200 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0250 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0300 3.0 6.0 9.0 12.0 15.0 18.0 21.0 24.0 27.0 30.0350 3.5 7.0 10.5 14.0 17.5 21.0 24.5 28.0 31.5 35.0400 4.0 8.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0500 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0600 6.0 12.0 18.0 24.0 30.0 36.0 42.0 48.0 54.0 60.0700 7.0 14.0 21.0 28.0 35.0 42.0 49.0 56.0 63.0 70.0800 8.0 16.0 24.0 32.0 40.0 48.0 56.0 64.0 72.0 80.0900 9.0 18.0 27.0 36.0 45.0 54.0 63.0 72.0 81.0 90.01000 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0

FACTOR X - HORSEPOWER REQUIRED TO OPERATE EMPTY CONVEYOR AT 350 FPMCon- Center-Center of PulleysveyorWidth 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 2.024" 0.9 1.1 1.2 1.4 1.6 1.8 2.0 2.1 2.3 2.530" 1.4 1.6 1.8 1.9 2.2 2.5 2.8 3.0 3.2 3.536" 1.8 2.0 2.1 2.6 2.9 3.1 3.4 3.8 4.2 4.442" 2.1 2.5 2.7 3.0 3.5 3.7 4.2 4.6 5.3 6.048" 2.7 2.8 3.2 3.4 3.7 4.2 5.3 5.6 6.2 6.7

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

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HOW TO DETERMINE CONVEYOR BELT SPEEDFive (5) factors are required to determine conveyorbelt speed.

A = Motor RPMB = Motor Sheave Dia. (inches)C = Reducer Sheave Dia. (inches)D = Reducer RatioE = Dia. of Pulley (inches)

A x B ÷ C = Reducer Input Speed (RPM)

Reducer Input Speed (RPM) ÷ D = Drive PulleyRPM

Drive Pulley RPM x 0.2618 x E = Conveyor BeltSpeed (FPM)

Example: Determine Conveyor Belt Speed of a 30" x60' conveyor with a 15 HP, 1750 RPM electric motordrive, 16" head pulley, 6.2" diameter motor sheave,9.4" diameter reducer sheave and a 15:1 reducer.

A = 1750 RPMB = 6.2C = 9.4D = 15E = 16

1750 x 6.2 ÷ 9.4 = 1154 RPM (Reducer Input)

1154 RPM ÷ 15 = 77 RPM (Pulley Speed)

77 RPM x 0.2618 x 16 = 322 FPM ConveyorBelt Speed

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.

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manufactures a variety of portable and stationary con-veyors designed to meet the customer’s requirements.As a rule of thumb, conveyors are designed with aClass I Drive, 220 PIW 2-ply belt, 5" CEMA B idlersand 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; verticalgravity take-up; horizontal gravity take-up; snub pulley;return belt covers; full hood top belt covers; impactidlers; self-training troughing idlers; self-training returnidlers; 220 PIW 2-ply belting with 3⁄16" top covers and1⁄16" bottom covers; 330 PIW 3-ply belting with 3⁄16" topcovers and 1⁄16" bottom covers; CEMA C idlers; walk-way with handrail, toeplate and galvanized decking;safety stop switch with cable tripline; discharge hood;wind hoops; balanced driveshaft; backstops; etc.

Series 2: Portable, channel frame conveyors. Usedprimarily as radial stacking conveyors with PortableScreening Plants. Come equipped with hydraulic dri-ves to be powered from an auxiliary source.

MODEL SIZE MOTOR2-2440 24" x 40' hyd. 2-2450 24" x 50' hyd. 2-3050 30" x 50' hyd.

NOTE: Series 2 are available with electric drive.

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Series 11: Portable, standard duty, lattice frame utilityconveyors. Used as transfer conveyors or radial stack-ing conveyors.

MODEL SIZE MOTOR11-2440 24" x 40' 7.5 HP 11-2450 24" x 50' 10 HP 11-2460 24" x 60' 10 HP 11-2470 24" x 70' 10 HP

11-3040 30" x 40' 10 HP 11-3050 30" x 50' 15 HP 11-3060 30" x 60' 15 HP 11-3070 30" x 70' 20 HP

11-3640 36" x 40' 15 HP 11-3650 36" x 50' 20 HP 11-3660 36" x 60' 20 HP 11-3670 36" x 70' 25 HP

11-4240 42" x 40" 25 HP11-4250 42" x 50" 30 HP11-4260 42" x 60" 30 HP11-4270 42" x 70" 40 HP

Other widths available upon request.

161

NOTE: Series 11 are available with hydraulic drive.

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Series 12: Portable, standard duty, lattice frame feedconveyors and surge bins. Series 11: 30" or 36" wideconveyors incorporate various hopper/feeder combi-nations.

• Gravity feed hoppers are used primarily in “freeflowing” materials and are installed directly over theconveyor tail end and are used with top loadingequipment.

• Feeder hoppers generally provide a more accuratemetering of material than does a gravity hopper.

• Belt feeder/hopper – belt feeders are commonlyused and recommended for handling sand andgravel and sticky materials, such as clay or topsoilthat tend to build-up in other types of feeders. Ahopper is mounted above the feeder for use withtop loading equipment.

• Reciprocating plate feeders/hoppers – recipro-cating plate feeders are used for free-flowing sandand gravel, to minimize impact directly to the con-veyor belt. A hopper is mounted above the feederfor use with top loading equipment.

• Gravity feed dozer trap is used primarily for “freeflowing” materials when push loading material witha dozer. Material feeds directly to conveyor belt.

• Belt feeder/dozer trap – includes belt feeder asdescribed above with feed coming from a dozer,pushing material into the dozer trap.

• Plate feeder/dozer trap – includes plate feeder asdescribed above with the feeder coming from adozer pushing material into the dozer trap.

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

MODEL SIZE MOTOR13-2480 24" x 80' 10 HP 13-24100 24" x 100' 15 HP 13-24125 24" x 125' 15 HP13-24150 24" x 150' 25 HP

13-3080 30" x 80' 20 HP 13-30100 30" x 100' 25 HP 13-30125 30" x 125' 25 HP13-30150 30" x 150' 40 HP

13-3680 36" x 80' 25 HP 13-36100 36" x 100' 30 HP 13-36125 36" x 125' 40 HP13-36150 36" x 150' 50 HP

13-4280 42" x 80' 40 HP 13-42100 42" x 100' 50 HP 13-42125 42" x 125' 60 HP13-42150 42" x 150' 75 HP

Other widths available upon request.

NOTE: Some Series 13 are available with hydraulic drive.

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Series 31: Portable, heavy duty, lattice frame radialstacking conveyors. Side-folding for road portability.

MODEL SIZE MOTOR31-2480 24" x 80' 10 HP 31-24100 24" x 100' 15 HP31-24125 24" x 125' 15 HP

31-3080 30" x 80' 20 HP31-30100 30" x 100' 25 HP31-30125 30" x 125' 25 HP

31-3680 36" x 80' 25 HP31-36100 36" x 100' 30 HP31-36125 36" x 125' 40 HP

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Series 33: Portable, heavy duty, telescoping radialstacking conveyors. Because of the stacker’s ability tomove in three directions: raise/lower, radial andextend/retract, it is effective in reducing segregationand degradation of material stockpiles.

Unique axle arrangement allows for quick set-up ofstacker. Road travel suspension of (8) eight 11:00-22.5tires on tandem walking beam axle. Gull wing radialstockpiling axle assembly of (4) four 385/65D-19.5tires. Gull wing is hydraulically actuated to lift traveltires off the ground for radial stockpiling. (2) Twohydraulic planetary power travel drives are included.

Automated stockpiling with PLC controls is availableon all models.

CONVEYORLENGTH MOTOR

RETRACTED/ MAIN CONV./MODEL SIZE EXTENDED EXT. CONV.33-30130 30" x 130' 70'/130' 20 HP/20 HP33-30150 30" x 150' 80'/150' 20 HP/20 HP33-36130 36" x 130' 70'/130' 30 HP/25 HP33-36136LP 36" x 136' 80'/136' 30 HP/25 HP33-36150 36" x 150' 80'/150' 30 HP/30 HP

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AR

EA

#3

AR

EA

#2

AR

EA

#1

TELESCOPING STACKER

CONVENTIONAL STOCKPILE

AREA #1

100%

NON-SEGREGATED STOCKPILE

AREA #2

63%

FULL CAPACITY

AREA #3

137%

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167

Series 35: In pit, heavy duty, fixed height radial stackers.

MODEL SIZE MOTOR35-24150 24" x 150' 25 HP 35-30150 30" x 150' 40 HP 35-36150 36" x 150' 60 HP

Other belt widths and lengths available.

MODEL SIZE MOTOR36-24100 24" x 100' 20 HP 36-24125 24" x 125' 20 HP 36-24150 24" x 150' 25 HP

36-30100 30" x 100' 30 HP 36-30125 30" x 125' 30 HP 36-30150 30" x 150' 40 HP

36-36100 36" x 100' 50 HP 36-36125 36" x 125' 50 HP 36-36150 36" x 150' 60 HP

Other belt widths and lengths available.

Series 36: In pit, heavy-duty, adjustable height, masttype cable suspended radial stackers.

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SPECIALTY CONVEYORS INCLUDE:• Series 40T: Transflite conveyors (also known asgrasshopper conveyors) which are semi-mobile,overland transfer conveyors. Standard sizes are24", 30", 36" belt widths x 60', 80', 100' lengths.May have a single axle near the discharge end orone skid type support. Transflite conveyors are eas-ily moved around in the pit. Other sizes areavailable.

• Series 47S: Stackable conveyors. Made with a 24"overall height frame of channel iron and angle withthe components recessed in the frame. Up to 8 con-veyors can be stacked on one trailer for multipleunit transport. Standard sizes are 24", 30" and 36"belt widths x 50' or 60' lengths. Often used as trans-fer conveyors in portable crushing and screeningspreads.

• Series 47SP: Portable 36" x 50' or 60' stackableconveyor with special hinged frame section andhold down wheels. Often used as under crusherdischarge conveyor or under the discharge chutesof portable screening plants where clearance isminimal. Also known as “Dogleg” conveyors.

Series 40: Interplant feed and transfer conveyors, sta-tionary conveyors and specialty conveyors. Includesoverland systems thousands of feet long to bring mate-rial from the mining area to the processing plant.

Standard belt widths are 24", 30", 36" and 42". Otherbelt widths are available. Lengths are built to specifi-cation. Standard frames are 8" channel, 24", 30", 36"and 42" deep angle iron lattice trusses.

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PUGMILLSINTRODUCTION:

Pugmills are used to blend together one or more dryingredients and/or liquid ingredients into a homoge-neous mixture. They were originally developed to mixan aggregate with a liquid bituminous material for acold mix asphalt. Today they are used for a number ofapplications including: cold mix asphalt; cementtreated base; soil remediation; etc.

The design is a continuous mix pugmill. It includes twoshafts with paddles on each shaft. The shafts are dri-ven by one drive with a set of timing gears between theshafts. The paddles, arranged in a spiral pattern over-lap, enhancing the quality of the mix. Max. feed size tothe pugmill is 2". The max. clearance between the pad-dle and the wall is 2". This can be adjusted to a min. of3/4". The paddles can also be rotated to increase wearlife, as well as increase retention time in the chamber.The pugmill also comes standard with replaceablewear liners, drop-out bottom for ease of clean-out, anda dam gate.

The pugmill is available in three sizes:

Model Size Motor Number of Paddles50-486 48" x 6' 60 HP 4050-488 48" x 8' 75 HP 4850-4810 48" x 10' 100 HP 64

The most convenient way to utilize a pugmill is on aportable chassis. We offer two (2) different configura-tions of portable plants.

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Model 52This plant features a 9 cu.yd. hopper with 36" beltfeeder, 30" incline feed conveyor and 4' x 6' pugmilllocated at the end of the plant. It is all electric with anoptional on-board genset. It comes on a portable chas-sis with standard travel features – fifth wheel hitch,brakes, lights and mudflaps. A second 6 cu.yd. hopperis available as an option.

Model 52SThis plant is similar to the Model 52, but larger withmore pugmill HP and higher capacity. It includes a 13cu.yd. primary hopper with 36" belt feeder, 11 cu.yd.secondary hopper with 36" belt feeder, 36" wide inclinefeed conveyor and a 4' x 8' pugmill located at the endof the plant. This plant is all electric and comes on aportable chassis. Genset optional.

170

(Model 52S shown)

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RAILROAD BALLASTBallast is a relatively coarse aggregate which

provides a stable load carrying base for trackage aswell as quick drainage. Ballast normally would becrushed quarry or slag materials: free of clay, silt, etc.

Two typical specifications follow, to provide someidea as to general gradations:

Sieve Example “A” Example “B”Opening Percent Passing Percent Passing

3" (76.2 mm) 100

21⁄2" (63.5 mm) 90 -100 100

2" (50.8 mm) 96 -100

11⁄2" (38.1 mm) 25 - 60 35 - 70

1" (25.4 mm) 0 - 153⁄4" (19.0 mm) 0 - 131⁄2" (12.7 mm) 0 - 5 0 - 5

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

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

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

Mixtures Approx. Quantities of Materials

C.A.F.A. (Gravel Cement

Cement (Sand) or Stone) in Sacks Cu. Ft. Cu. Yd. Cu. Ft. Cu. Yd.

1 1.5 15.5 23.2 0.861 2.0 12.8 25.6 0.951 2.5 11.0 27.5 1.021 3.0 9.6 28.8 1.07

1 1.5 3 7.6 11.4 0.42 22.8 0.851 2.0 2 8.3 16.6 0.61 16.6 0.611 2.0 3 7.0 14.0 0.52 21.0 0.781 2.0 4 6.0 12.0 0.44 24.0 0.89

1 2.5 3.5 5.9 14.7 0.54 20.6 0.761 2.5 4 5.6 14.0 0.52 22.4 0.831 2.5 5 5.0 12.5 0.46 25.0 0.921 3.0 5 4.6 13.8 0.51 23.0 0.85

Fine Aggregate Coarse Aggregate

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CubicalSize(in.) 145 150 155 160 165 170 175 180 185

5 10 11 11 12 12 12 13 13 136 18 19 19 20 21 21 22 23 237 29 30 31 32 33 34 35 36 378 43 44 46 47 49 50 52 53 559 61 63 65 68 70 72 74 76 7810 84 87 90 93 95 98 101 104 10711 112 116 119 123 127 131 135 139 14212 145 150 155 160 165 170 175 180 18513 184 191 197 203 210 216 222 229 23514 230 238 246 254 262 270 278 286 29415 283 293 302 312 322 332 342 351 36116 344 356 367 379 391 403 415 426 43817 412 426 440 454 469 483 497 511 52618 489 506 523 539 556 573 590 607 62419 575 595 615 634 654 674 694 714 73420 671 694 717 740 763 786 810 833 85622 893 925 954 985 1016 1047 1078 1108 113924 1160 1200 1239 1279 1319 1359 1399 1439 147925 1475 1526 1575 1626 1677 1728 1779 1830 188128 1842 1905 1967 2031 2094 2158 2222 2285 234930 2265 2343 2419 2498 2576 2654 2732 2811 288932 2749 2844 2936 3031 3126 3221 3316 3411 350634 3298 3412 3522 3636 3750 3864 3978 4092 420636 3914 4050 4180 4316 4451 4586 4722 4857 499239 4978 5150 5321 5493 5664 5836 6008 6179 6351

RIPRAP

Weights of Riprap—Pounds

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

Solid Rock Density—Lbs. Per Ft.3 (Approx.)

Riprap as used for facing dams, canals and waterwaysis normally a coarse, graded material. Typical generalspecifications would call for a minimum 160 lb./ft.3stone, free of cracks and seams with no sand, clay,dirt, etc. A typical specification will probably give thepercent passing by particle weight such as:

Percent Passing 15" Blanket 24" Blanket

100 165 lbs. 670 lbs.50 - 70 50 lbs. 200 lbs.30 - 50 35 lbs. 135 lbs.0 - 15 10 lbs. 40 lbs.

In order to relate the above weights to rock size, referto the following size/density chart:

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1 3.3 14 1⁄2 * 15 1.7 14 1⁄2 * 1511⁄2 4.7 14 1⁄2 * 15 2.4 14 1⁄2 * 152 6 14 1⁄2 * 20 3.0 14 1⁄2 * 15 3 9 14 1⁄2 * 30 4.5 14 1⁄2 * 155 15 12 1⁄2 * 45 7.5 14 1⁄2 * 2571⁄2 22 8 3⁄4 � 60 11 14 1⁄2 � 3010 27 8 3⁄4 � 70 14 12 1⁄2 � 3515 38 6 11⁄4 � 80 19 10 3⁄4 � 5020 52 4 11⁄4 �110 26 8 3⁄4 � 7025 64 3 11⁄4 �150 32 6 11⁄4 � 7030 77 1 11⁄2 �175 39 6 11⁄4 � 8040 101 00 2 �200 51 4 11⁄4 �10050 125 000 2 �250 63 3 11⁄4 �12560 149 200,000

C.M. 21⁄2 �300 75 1 11⁄2 �15075 180 0000 21⁄2 �300 90 0 2 �200100 245 500 3 �500 123 000 2 �250125 310 750 31⁄2 �500 155 0000 21⁄2 �350150 360 1000 4 �600 180 300 21⁄2 �400200 480 240 500 3 �500250 580 290300 696 348

173

MOTOR WIRING AT STANDARD SPEEDSFrom National Electrical Code

Single-Phase Induction Motors

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

3-Phase Squirrel-Cage Induction Motors

��Min. **Max. ��Min. **MaxFull Size Size Rating Full Size Size RatingLoad Wire Con- of Load Wire Con- of

HP. Amp. AWG duit Branch Amp. AWG duit BranchPer Rubber in Circuit Per Rubber in Circuit

Phase Covered Inches Fuses Phase Covered Inches Fuses

1⁄2 7 14 1⁄2 25 3.5 14 1⁄2 153⁄4 9.4 14 1⁄2 30 4.7 14 1⁄2 151 11 14 1⁄2 35 5.5 14 1⁄2 2011⁄2 15.2 12 1⁄2 45 7.6 14 1⁄2 252 20 10 3⁄4 60 10 14 1⁄2 303 28 8 3⁄4 90 14 12 1⁄2 455 46 4 11⁄4 150 23 8 3⁄4 7071⁄2 34 6 1 11010 43 5 11⁄4 125

120 Volts 230 Volts

230 Volts 460 Volts

‡‡

‡‡‡

Page 174: Facts Figures Book

1 8.4 14 1⁄2 15 4.2 14 1⁄2 1511⁄2 12.5 12 1⁄2 20 6.3 14 1⁄2 152 16.1 10 3⁄4 25 8.3 14 1⁄2 153 23 8 3⁄4 35 12.3 12 1⁄2 205 40 6 1 60 19.8 10 3⁄4 3071⁄2 58 3 11⁄4 90 28.7 6 1 4510 75 1 11⁄2 125 38 6 1 6015 112 00 2 175 56 4 11⁄4 9020 140 000 2 225 74 1 11⁄2 12525 184 300 21⁄2 300 92 0 2 15030 220 400 3 350 110 00 2 17540 292 700 31⁄2 450 146 0000 21⁄2 22550 360 1000 4 600 180 300 21⁄2 30060 215 400 3 35075 268 600 31⁄2 450100 355 1000 4 600

Horsepower 1800 RPM 1200 RPM2 145T 184T3 182T 213T5 184T 215T71⁄2 213T 254T10 215T 256T

15 254T 284T20 256T 286T25 284T 324T30 286T 326T40 324T 364T

50 326R 365T60 364T 404T75 365T 405T

174

MOTOR WIRING AT STANDARD SPEEDS, (Continued)

From National Electrical Code

DIRECT CURRENT MOTORS

NEMA Frame Numbers for Polyphase Induction Motors

��Min. **Max. ��Min. **MaxFull Size Size Rating Full Size Size RatingLoad Wire Con- of Load Wire Con- of

HP. Amp. AWG duit Branch Amp. AWG duit BranchPer Rubber in Circuit Per Rubber in Circuit

Phase Covered Inches Fuses Phase Covered Inches Fuses

115 Volts

“T” Frame

230 Volts

‡‡‡‡

‡‡‡‡

M.C.M.In order to avoid excessive voltage drop where long runs are involved, it may benecessary to use conductors and conduit of sizes larger than the minimum sizes listedabove.Branch-circuit fuses must be large enough to carry the starting current, hence theyprotect against short-circuit only. Additional protection of an approved type must beprovided 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 forfull-voltage starting of high-reactance, low starting current squirrel-cage motors.

‡��

**

*�

Page 175: Facts Figures Book

175

DIMENSIONS, IN INCHES, OF ELECTRIC MOTORSBy NEMA Frame Number

M + N D E F U V Keyway

182T 73⁄4 41⁄2 33⁄4 21⁄4 11⁄8 21⁄2 1⁄4 x 1⁄8184T 81⁄4 41⁄2 33⁄4 23⁄4 11⁄8 21⁄2 1⁄4 x 1⁄8213 91⁄4 51⁄4 41⁄4 23⁄4 11⁄8 23⁄4 1⁄4 x 1⁄8213T 95⁄8 51⁄4 41⁄4 23⁄4 13⁄8 31⁄8 5⁄16 x 5⁄32215 10 51⁄4 41⁄4 31⁄2 11⁄8 23⁄4 1⁄4 x 1⁄8215T 103⁄8 51⁄4 41⁄4 31⁄2 13⁄8 31⁄8 5⁄16 x 5⁄32254T 123⁄8 61⁄4 5 41⁄8 15⁄8 33⁄4 3⁄8 x 3⁄16254U 121⁄8 61⁄4 5 41⁄8 13⁄8 31⁄2 5⁄16 x 5⁄32256T 131⁄4 61⁄4 5 5 15⁄8 33⁄4 3⁄8 x 3⁄16256U 13 61⁄4 5 5 13⁄8 31⁄2 5⁄16 x 5⁄32284T 141⁄8 7 51⁄2 43⁄4 17⁄8 43⁄8 1⁄2 x 1⁄4284U 143⁄8 7 51⁄2 43⁄4 15⁄8 45⁄8 3⁄8 x 3⁄16286T 147⁄8 7 51⁄2 51⁄2 17⁄8 43⁄8 1⁄2 x 1⁄4286U 151⁄8 7 51⁄2 51⁄2 15⁄8 45⁄8 3⁄8 x 3⁄16324T 153⁄4 8 61⁄4 51⁄4 21⁄8 5 1⁄2 x 1⁄4324U 161⁄8 8 61⁄4 51⁄4 17⁄8 53⁄8 1⁄2 x 1⁄4326T 161⁄2 8 61⁄4 6 21⁄8 5 1⁄2 x 1⁄4326U 167⁄8 8 61⁄4 6 17⁄8 53⁄8 1⁄2 x 1⁄4364T 173⁄8 9 7 55⁄8 23⁄8 55⁄8 5⁄8 x 5⁄16364U 177⁄8 9 7 55⁄8 21⁄8 61⁄8 1⁄2 x 1⁄4365T 177⁄8 9 7 61⁄8 23⁄8 55⁄8 5⁄8 x 5⁄16365U 183⁄8 9 7 61⁄8 21⁄8 61⁄8 1⁄2 x 1⁄4404T 20 10 8 61⁄8 27⁄8 7 3⁄4 x 3⁄8404U 197⁄8 10 8 61⁄8 23⁄8 67⁄8 5⁄8 x 5⁄16405T 203⁄4 10 8 67⁄8 27⁄8 7 3⁄4 x 3⁄8405U 205⁄8 10 8 67⁄8 23⁄8 67⁄8 5⁄8 x 5⁄16444U 233⁄8 11 9 71⁄4 27⁄8 83⁄8 3⁄4 x 3⁄8445U 243⁄8 11 9 81⁄4 27⁄8 83⁄8 3⁄4 x 3⁄8

Page 176: Facts Figures Book

176

AWG

Amp

Amp

Diameter

Amp*

Diameter

Size

Capacity

2 Cond.

3 Cond.

4 Cond.

Capacity

(Inches)

Capacity

(Inches)

250 MCM

275

2.39

4/0

245

2.04

210

2.26

3/0

220

1.89

190

2.07

2/0

190

1.75

170

1.93

1/0

160

1.65

145

1.79

1145

1.51

125

1.68

2130

1.34

110

1.48

3110

1.24

951.34

495

1.17

851.27

675

1.01

601.10

855

0.91

500.99

1025

.640

.690

.750

1220

.605

.640

.670

1415

.530

.560

.605

1610

.405

.430

.485

187

.390

.405

.435

CUR

REN

T CA

RRY

ING

CAP

ACIT

IES

AND

CAB

LE D

IAM

ETER

SIZ

ES F

OR

TH

E PO

RTAB

LE C

ABLE

S

Diameter (Inches)

Type SO Cord

3 Conductor Type “G”

4 Conductor Type “W”

*When using 4 conductor type “W” cable on 3 phase circuit with 4th conductor used as

ground, use amp capacity for 3 conductor type “G” cable.

Above Data from Western Insulated

Wire Co. fro Bronco 66 Certified Cable

Page 177: Facts Figures Book

177

GENERATOR SIZE TO POWERELECTRIC MOTORS ON CRUSHING

AND SCREENING PLANTSThe minimum generator size to power a group ofmotors should be selected on the basis of the fol-lowing rules which allow all motors to operatesimultaneously with complete freedom of startingsequence.

A. GENERATOR KW—0.8 x total electric nameplate horsepower.

B. GENERATOR KW—2 x name plate horse-power of the largest electric motor withacross-the-line starter.

C. GENERATOR KW—1.5 x name plate horse-power of the largest electric motor withreduced voltage starting (with 80 percent start-ing voltage).

D. GENERATOR KW—2.25 x name plate horse-power of the largest electric motor with partwinding starting.

For across-the-line starting, use the larger of thetwo values determined from A and B.

For reduced voltage starting, use the larger of thetwo values determined from A and C.

For part winding starting, use the larger of the twovalues determined from A and D.

For combinations of the above starting types, usethe largest value determined from A, B, C, and Das they apply.

Page 178: Facts Figures Book

178

DREDGE PUMP

Above information can be used as a guide in pre-liminary selection of material handlingcomponents. For plants charged by dredgepumps, proper selection of sand processing com-ponents is in part controlled by maximum amountof water in the slurry.

Prior to final selection of machinery, completeinformation must be assimilated so sound judge-ment can be exercised.

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 = TPHTPH X 17.6 = GPM

Page 179: Facts Figures Book

179

VELOCITY OF FLOW IN PIPES

4000

3000

2500

2000

1500

1000900800700

600

500

400

300

200

150

10090807060

50

40

30

25

20

4000

3000

2500

2000

1500

1000900800700

600

500

400

300

200

150

10090807060

50

40

30

25

203 4 5 6 7 8 9 10 11 12 13 14 15 16 17

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

VELOCITY - FEET PER SECOND

VELOCITY - FEET PER SECOND

VELOCITY OF FLOW IN PIPES

STD PIPE SIZE

1"

2"

3"

4"

5"

6"

8"

10"

12"

1-1/4"

1-1/2"

2-1/2"

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

1" . . . . . 1.049" 21⁄2" . . . . 2.469" 6" . . . . . 6.065"11⁄4" . . . . 1.380" 3". . . . . . 3.068" 8" . . . . . 7.981"11⁄2" . . . . 1.610" 4". . . . . . 4.026" 10" . . . 10.020"2" . . . . . 2.067" 5". . . . . . 5.047" 12" . . . 11.938"

Page 180: Facts Figures Book

180

FRICTION LOSS IN PIPES

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

10.1 .2 .3 .4 .5 .6 .8 2 3 4 5 6 8 10 20 30 40 501.0

.1 .2 .3 .4 .5 .6 .8 2 3 4 5 6 8 10 20 30 40 501.0

20

30

40

50607080

100

100

200

300

400

500600700800

1000

1000

2000

3000

4000

5000

10

20

30

40

50607080

100

100

200

300

400

500600700800

1000

1000

2000

3000

4000

5000

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

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

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

12"12"12"

10"10"10"

8"8"8"

6"6"6"

5"5"5"

4"4"4"

3"3"3"

2-1/2"2-1/2"2-1/2"

2"2"2"

1-1/2"1-1/2"1-1/2"

1-1/4"1-1/4"1-1/4"

1"1"1"

Page 181: Facts Figures Book

181

FLOW OVER WEIRSSettling Tanks, Classifiers, Sand Preps, Flumes

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

Multiply figure from curve by length of weir.

FLUME OR LAUNDERUse a bevel-edge steel plate or board with sharp edgeupstream.

L(Weir length) and D (depth of water behind weir) musteach be at least three times h.

Water or slurry must fall free of weir; i.e., with air spaceunderneath. If possible, drill air holes in side of launderon downstream side of weir plate.

Curve does not apply to triangular or notched weirs.

250

1

2

3

4

5

0

1

2

3

4

5

50 75 100 150 200 250 300 400

25 50 75 100 150 200 250 300 400

GPM OVERFLOW PER FOOT OF WEIR

OV

ER

FL

OW

DE

PT

H (

H)

IN IN

CH

ES

OV

ER

FL

OW

DE

PT

H (

H)

IN IN

CH

ES

GPM OVERFLOW PER FOOT OF WEIR

Settling Tanks, Classifiers, Sand Preps, Flumes

Page 182: Facts Figures Book

182

SPRAY NOZZLESFOR VIBRATING SCREENS

The introduction of water under pressure over thevibrating screens often greatly improvesscreening efficiency as well as aiding in theremoval of deleterious materials on the individualaggregate particles. We utilize Type WF FlatSpray Nozzles over the screens to produce auniform, flat spray pattern without hard edges atpressures of 5 psi and up. Tapered edges of thespray pattern permits pattern overlap with evendistribution of the spray. The impact of spray isgenerally greater with narrower spray angles,assuming the same flow rate.

AVAILABLE SPRAY ANGLESNozzle Size

0° — All sizes15° — All sizes thru WF 15025° — All sizes thru WF 15040° — All sizes thru WF 15050° — All sizes thru WR 20065° — All sizes80° — All sizes90° — All sizes thru WF 250

Page 183: Facts Figures Book

TYPE

WF

CAPA

CITY

CH

ART

Noz

zle Num

ber—

Capa

city at 4

0 PS

I

SHAD

ED COLU

MNS IN

DICAT

E MOST

AVA

ILAB

LE SIZES

.

NO

ZZLE

Equi

v.N

UM

BER

Ori

f.PI

PE S

IZE

CAPA

CITY

— G

PM A

T PS

I PR

ESSU

RE

Mal

eN

o.D

ia.

1 ⁄81 ⁄4

3 ⁄81 ⁄2

3 ⁄440

6080

100

150

200

300

400

500

600

700

800

1000

WFM

2.034

.20

.24

.28

.32

.39

.45

.55

.63

.71

.77

.84

.89

1.0

WFM

4.052

.40

.49

.57

.63

.77

.89

1.1

1.3

1.4

1.6

1.7

1.8

2.0

WFM

4.5

.055

.45

.55

.64

.71

.87

1.0

1.2

1.4

1.5

1.7

1.9

2.0

2.2

WFM

5.057

.50

.61

.71

.79

.97

1.1

1.4

1.6

1.8

1.9

2.1

2.2

2.5

WFM

5.5

.060

.55

.67

.78

.87

1.1

1.2

1.5

1.7

1.9

2.1

2.3

2.5

2.8

WFM

6.062

.60

.73

.85

.95

1.2

1.3

1.6

1.9

2.1

2.3

2.5

2.7

3.0

WFM

6.064

.65

.80

.92

1.0

1.3

1.5

1.8

2.1

2.3

2.5

2.7

2.9

3.3

WFM

7.067

.70

.86

.99

1.1

1.4

1.6

1.9

2.2

2.5

2.7

2.9

3.1

3.5

WFM

8.072

.80

.98

1.1

1.3

1.5

1.8

2.2

2.5

2.8

3.1

3.4

3.6

4.0

WFM

8.5

.074

.85

1.1

1.2

1.3

1.6

1.9

2.3

2.7

3.0

3.3

3.6

3.8

4.2

WFM

9.076

.90

1.1

1.3

1.4

1.7

2.0

2.5

2.8

3.2

3.5

3.8

4.0

4.5

WFM

10.080

1.0

1.2

1.4

1.6

1.9

2.2

2.7

3.2

3.5

3.9

4.2

4.5

5.0

183

Page 184: Facts Figures Book

TYPE

WF

CAPA

CITY

CH

ART—

Noz

zle Num

ber—

Capa

city at 4

0 PS

I

SHAD

ED COLU

MNS IN

DICAT

E MOST

AVA

ILAB

LE SIZES

.

184

NO

ZZLE

Equi

v.N

UM

BER

Ori

f.PI

PE S

IZE

CAPA

CITY

— G

PM A

T PS

I PR

ESSU

RE

Mal

eN

o.D

ia.

1 ⁄81 ⁄4

3 ⁄81 ⁄2

3 ⁄410

1520

3040

6080

100

150

200

300

400

500

WFM

*15

3 ⁄32.75

.92

1.1

1.3

1.5

1.8

2.1

2.4

2.9

3.4

4.1

4.7

5.3

WFM

207 ⁄64

1.0

1.2

1.4

1.7

2.0

2.5

2.8

3.2

3.9

4.5

5.5

6.3

7.1

WFM

309 ⁄64

1.5

1.8

2.1

2.6

3.0

3.7

4.2

4.7

5.8

6.7

8.2

9.5

10.6

WFM

405 ⁄32

2.0

2.5

2.8

3.5

4.0

4.9

5.7

6.3

7.7

9.0

11.0

12.7

14.2

WFM

5011⁄64

2.5

3.1

3.5

4.3

5.0

6.1

7.1

7.9

9.7

11.2

13.7

15.8

17.7

WFM

603 ⁄16

3.0

3.7

4.2

5.2

6.0

7.3

8.5

9.5

11.6

13.4

16.4

19.0

21.2

WFM

*70

13⁄64

3.5

4.3

4.9

6.1

7.0

8.6

9.9

11.1

13.5

15.7

19.2

22.2

24.8

WFM

807 ⁄32

4.0

5.0

5.6

5.8

8.0

9.8

11.4

12.6

15.4

17.9

21.9

25.3

28.3

WFM

100

1 ⁄45.0

6.1

7.1

8.6

10.0

12.2

14.1

15.8

19.4

22.3

27.4

31.6

35.3

WFM

150

19⁄64

7.5

9.2

10.6

13.0

15.0

18.4

21.2

23.7

29.0

33.5

41.1

47.4

53.1

WFM

200

11⁄32

10.0

12.2

14.1

17.3

20.0

24.5

28.3

31.6

38.7

44.3

54.7

63.3

70.8

WFM

250

25⁄64

12.5

15.7

17.7

21.6

25.0

30.5

35.4

39.4

48.4

55.8

68.4

79.0

88.4

WFM

300

27⁄64

15.0

18.4

21.2

26.0

30.0

36.8

42.4

47.4

58.0

66.9

82.1

94.8

106.0

WFM

400

1 ⁄220

.224

.428

.234

.640

.049

.056

.663

.277

.489

.511

0.0

127.0

141.0

Page 185: Facts Figures Book

185

DIMENSIONS AND WEIGHTS FOR TYPE WF

WATER VOLUME REQUIRED FOR WASHINGAGGREGATESThe amount of water required for washing aggregates underaverage conditions is 3 to 5 GPM of water for each TPH ofmaterial fed to a washing screen. The finer the feedgradation, the more GPM of water required.

GETTING MAXIMUM WASHED PRODUCTFROM A VIBRATING SCREENScreen efficiency can be greatly increased by applying waterdirectly to the feed box located ahead of the vibrating screen.Water volume applied must be sufficient to form a slurry inthe feed box so that effective screening begins immediatelywhen the wet product contacts the screen.

DIMENSIONS (Inches)PIPE WEIGHTSIZE TYPE A B C (Ounces)

1⁄8 WFM 11⁄16 7⁄16 5⁄16 .41⁄4 WFM 31⁄32 9⁄16 3⁄8 .73⁄8 WFM 1 11⁄16 7⁄16 1.11⁄2 WFM 117⁄64 7⁄8 1⁄2 2.53⁄4 WFM 127⁄64 11⁄16 5⁄8 5.0

Page 186: Facts Figures Book

186

WEIGHTS AND MEASURES—UNITED STATES

Linear Measure

8 furlongs80 chains

1 mile = 320 rods1760 yards5280 feet10 chains

1 furlough = 220 yards6.06 rods

1 station = 33.3 yards100 feet

4 rods22 yards

1 chain = 66 feet100 links5.5 yards

1 rod = 16.5 feet3 feet

1 yard = 36 inches1 foot = 12 inches

1 link = 7.92 inches1 statute mile = 80 chains

100 links1 chain = 4 rods

66 feet22 yards

Gunter’s or Surveyor’s Chain Measure

36 sections1 township = 36 sq. miles

1 section1 sq. mile = 640 acres

4,840 sq. yards1 acre = 43,560 sq. feet

160 sq. rods

2721⁄4 sq. feet1 sq. rod = 301⁄4 sq. yards

1,296 sq. inches1 sq. yard = 9 sq. feet1 sq. foot = 144 sq. inches

Land Measure

1 cubic yard = 27 cubic feet1 cord (wood) = 4x4x8 ft. = 128 cu. ft.1 ton (shipping) = 40 cubic ft.

1 cu. ft. = 1728 cu. in.1 bushel = 2150.42 cu. in.1 gallon = 231 cu. in.

Cubic Measure

1 long ton = 2250 lbs.1 short ton = 2000 lbs.

1 pound = 16 ounces1 ounce = 16 drams

Weights (Commercial)

12 ounces1 pound = 5760 grains

20 pennyweights1 ounce = 480 grains

Troy Weight (For Gold and Silver)

1 pennyweight = 24 grains

= 4 gills (gl.)1 pint (pt.) = 28.875 cu. in.

= 2 pints1 quart (qt.) = 57.75 cu. in.

4 quarts8 pints

1 gallon (gal.) = 32 gills231 cu. in.81⁄2 lbs. @ 62°F

1 hogshead = 63 gallons1 barrel = 311/2 gallons1 cu. ft. 7.48 U.S. gals.water = 1728 cu. in.

621⁄2 lbs. @ 62°F

Liquid Measure

{

{

{

{

{

{

{

{

{ {{

{

{

{

{{

{{

Page 187: Facts Figures Book

187

WEIGHTS AND MEASURES—UNITED STATES

Dry Measure

2 pints (pt.)1 quart (qt.) = 67.20 cu. in.

8 quarts1 peck (pk.) = 16 pints

537.605 cu. in.

4 pecks1 bushel (bu. ) = 32 quarts

2150.42 cu. in.

(When necessary to distinguish the dry pint or quart from the liquid pint orquart, the word “dry” should be used in combination with the name or abbre-viation of the dry unit.)

1 fathom = 6 feet1 cable length = 120 fathoms1 nautical mile = 6,080 feet

1 marine league = 3 marine miles71⁄2 cable lengths

1 statute mile = 5,280 feet

Mariner’s Measure

.0236 horsepower17.6 watts

1 BTU per minute = .0176 kilowatts778 foot lbs. per min.

.0226 watts1 ft. lb. per minute = .001285 BTU per min.

746 watts.746 kilowatts

1 horsepower = 33,000 ft. lbs. per min.42.4 BTU per min.

.00134 horsepower1 watt = .001 kilowatts

44.2 ft. lbs. per min..0568 BTU per min.1.341 horsepower

1 kilowatt = 1000 watts44.250 ft. lbs. per min.

56.8 BTU per min.

Measures of Power

1 sq. centimeter = 100 sq. milli-(cm2) meters (mm2)

1,000,000 mm2

1 sq. meter (m2) = 10,000 cm2

1 are (a) = 100 m2

10,000 m2

1 hectare (ha) = 100 a1 sq. kilometer = 1,000,000 m2

(km2) 100 ha

WEIGHTS AND MEASURES—METRICArea Measure

1 centimeter (cm)= 10 milli-meters (mm)100 mm

1 decimeter (dm) = 10 cm1,000 mm

1 meter (m) = 10 dm

1 dekameter (dkm) = 10 m100 m

1 hectometer (hm) = 10 dkm1,000 m

1 kilometer (km) = 10 hm

Linear Measure

1 centigram (cg) = 10 milligrams(mg)

100 mg1 decigram (dg) = 10 cg

1,000 mg1 gram (g) = 10 dg.

100g1 hectogram (hg) = 10 dkg1 dekagram (dkg) = 10 g

1,000 g1 kilogram (kg) = 10 hg1 metric ton (1) = 1,000 kg

Weight

{{{

{

{

{

{{

{{

{{

{{

{

{

{

{{{

Page 188: Facts Figures Book

188

WEIGHTS AND MEASURES—METRIC (Continued)

Cubic Measure1 cubic centimeter (cm3) = 1,000 cubic millimeters (mm3)

1,000,000 mm3

1 cubic decimeter (dm3) = 1,000 cm3

1 stere1,000,000,000 mm3

1 cubic meter (m3) = 1,000,000 cm3

1,000 dm3

METRIC-U.S. CONVERSION FACTORS(Based on National Bureau of Standards)

Sq. cm. x 0.1550 = sq. ins. Sq. ins. x 6.4516 = sq. cmSq. m. x 10.7639 = sq. ft. Sq. ft. x 0.0929 = sq. mAres x 1076.39 = sq. ft. Sq. ft. x 0.00093 = aresSq. m x 1.1960 = sq. yds. Sq. yds. x 0.8361 = sq. mHectare x 2.4710 = acres Acre x 0.4047 = hectaresSq. km x 0.3861 = sq. miles Sq. miles x 2.5900 = sq. km

1 centiliter (cl) = 10 milliliters (ml)100 ml

1 deciliter (dl) = 10 cl1,000 ml

1 liter* (l) = 10 dl

1 dekaliter (dkl) = 10 l100 l

1 hectoliter (hl) = 10 dkl1,000 l

1 kiloliter (kl) = 10 hl

Volume Measure

.986 U.S. horsepower1 metric horsepower = 736 watts 32,550 ft. lbs. per min.

.736 kilowatts 41.8 BTU per min.

Power

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

Area

Kgs per sq. cm x 14.223 = lbs. per sq. in.Lbs. per sq. in. x 0.0703 = kgs per sq. cmKgs per sq. in. x 0.2048 = lbs. per sq. ft.Kgs per sq. m x .204817 = lbs. per sq. ft.Lbs. per sq. ft. x 4.8824 = kgs per sq. mKgs per sq. m x .00009144 = tons (long) per sq. ft.

Pressure

Centimeters x 0.3937 = inches Inches x 2.5400 = centimetersMeters x 3.2808 = feet Feet x 0.3048 = metersMeters x 1.0936 = yards Yards x 0.9144 = metersKilometers x 0.6214 = miles* Miles* x 1.6093 = kilometersKilometers x 0.53959 = miles** Miles** x 1.85325 = kilometers

*Statute miles **Nautical miles

Length

Cu. ft. per min. x 0.028314 = cu. m per min.Cu. m per min. x 35.3182 = cu. ft. per min.

Flow

Metric horsepower x .98632 = U.S. horsepowerU.S. horsepower x 1.01387 = metric horsepower

Power

{

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189

Tons (long) per sq. ft. x 10940.0 = kg per sq. mKgs per sq. mm x .634973 = tons (long) per sq. in.Tons (long) per sq. in. x 1.57494 = kg per sq. mmKgs per cu. m x .062428 = lbs. per cu. ft.Lbs. per cu. ft x 16.0184 = kgs per cu. mKgs per m x .671972 = lbs. per ft.Lbs. per ft. x 1.48816 = kgs per mKg/m x 7.233 = ft. lbs.Ft. lbs. x .13826 = kg/mKgs per sq. com x 0.9678 = normal atmosphereNormal atmosphere x 1.0332 = kgs per sq cm

Board feet x 144 sq. in. x 1 in. = cubic inchesBoard feet x .0833 = cubic feetCubic feet x 6.22905 = gallons, Br. Imp.Cubic feet x 2.38095 x 10-2 = tons, Br. shippingCubic feet x .025 = tons, U.S. shippingDegrees, angular x .0174533 = radiansDegrees, F. (less 32°F) x .5556 = degrees, CentigradeDegrees, centigrade x 1.8 plus 32 = degrees, F.Gallons, Br. Imp. x .160538 = cubic feetGallons, Br. Imp. x 4.54596 = litersGallons, U.S. x .13368 = cubic feetGallons, U.S. x 3.78543 = litersLiters x .219975 = gallons, Br. Imp.Miles, statute x .8684 = miles, nauticalMiles, nautical x 1.1516 = miles, statuteRadians x 57.29578 = degrees, angularTons, long x 1.120 = tons, shortTons, short x .892857 = tons, longTons, Br. shipping x 42.00 = cubic feetTons, Br. shipping x .952381 = tons, U.S. shippingTons, U.S. shipping x 40.00 = cubic feetTons, U.S. shipping x 1.050 = tons, Br. shipping

Note: Br. Imp = British Imperial

METRIC-U.S. CONVERSION FACTORS (Continued)

Pressure (Continued)

Grams x 15.4324 = grains Grains x 0.0648 = gGrams x 0.0353 = oz. Oz. x 28.3495 = gGrams x 0.0022 = lbs. Lbs. x 453.592 = gKgs x 2.2046 = lbs. Lbs. x 0.4536 = kgKgs x 0.0011 = tons (short) Lbs. x 0.0004536 = tons*Kgs x 0.00098 = tons (long) Tons (short) x 907.1848 = kgTons* x 1.1023 = ton (short) Tons (short) x 0.9072 = tons*Tons* x 2204.62 = lbs. Tons (long) x 1016.05 = kg

Weight

Cu. cm. x 0.0610 = cu. in. Cu. ins. x 16.3872 = cu. cmCu. m x 35.3145 = cu. ft. Cu. ft. x 0.0283 = cu. mCu. m x 1.3079 = cu. yds. Cu. yds. x 0.7646 = cu. mLiters x 61.0250 = cu. in. Cu. ins. x 0.0164 = litersLiters x 0.0353 = cu. ft. Cu. ft. x 27.3162 = litersLiters x 0.2642 = gals. (U.S.) Gallons x 3.7853 = litersLiters x 0.0284 = bushels (U.S.) Bushels x 35.2383 = liters

Volume

Miscellaneous Conversion Factors

1000.027 = cu. cmLiters x 1.0567 = qt. (liquid) or 0.9081 = qt. (dry)

2.2046 = lb. of pure water at 4°C = 1 kg.{

Page 190: Facts Figures Book

190

APPROXIMATE WEIGHT OF MATERIALSWeight, Weight, Weight,

MATERIAL lbs./ft3 lbs./yd3 kg./m3

Andesite, Solid . . . . . . . . . . . . . . . . . . . . . . . 173 4,660 2,771Ashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 1,100 657Basalt, Broken . . . . . . . . . . . . . . . . . . . . . . . . 122 3,300 1954Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 5,076 3012

Caliche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2,430 1442Cement, Portland . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Mortar, Portland, 1:21⁄2 . . . . . . . . . . . . . . . . 135 3,654 2162

Cinders, Blast Furnace. . . . . . . . . . . . . . . . . . 57 1,539 913Coal, Ashes and Clinkers. . . . . . . . . . . . . . . 40 1,080 641

Clay, Dry Excavated. . . . . . . . . . . . . . . . . . . . 68 1,847 1089Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . 114 3,080 1826Dry Lumps . . . . . . . . . . . . . . . . . . . . . . . . . 67 1,822 1073Wet Lumps . . . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Compact, Natural Bed . . . . . . . . . . . . . . . . . 109 2,943 1746

Clay and Gravel, Dry . . . . . . . . . . . . . . . . . . . 100 2,700 1602Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 3,085 1826

Concrete, Asphaltic . . . . . . . . . . . . . . . . . . . . 140 3,780 2243Gravel or Conglomerate . . . . . . . . . . . . . . . 150 4,050 2403Limestone with Portland Cement . . . . . . . . 148 3,996 2371

Coal, Anthracite, Natural Bed. . . . . . . . . . . . . 94 2,546 1506Broken. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 1,857 1105Bituminous, Natural Bed . . . . . . . . . . . . . . . 84 2,268 1346Broken. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 1,413 833

Cullett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100 2,160-2,700 1281-1602Dolomite, Broken . . . . . . . . . . . . . . . . . . . . . 109 2,940 1746Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 4,887 2809

Earth, Loam, Dry Excavated . . . . . . . . . . . . . 78 2,100 1249Moist Excavated . . . . . . . . . . . . . . . . . . . . . 90 2,430 1442Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Dense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3,375 2002Soft Loose Mud. . . . . . . . . . . . . . . . . . . . . . 108 2,196 1730Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 2,565 1522

Gneiss, Broken . . . . . . . . . . . . . . . . . . . . . . . 116 3,141 1858Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 4,833 2,867

Granite, Broken or Crushed. . . . . . . . . . . . . . 103 2,778 1650Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 4,525 2691

Gravel, Loose, Dry. . . . . . . . . . . . . . . . . . . . . 95 2,565 1522Pit Run, (Gravelled Sand) . . . . . . . . . . . . . . 120 3,240 1922Dry 1⁄4 - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . 105 2,835 1682Wet 1⁄2 - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3,375 2002

Gravel, Sand & Clay, Stabilized, Loose . . . . . 100 2,700 1602Compacted . . . . . . . . . . . . . . . . . . . . . . . . . 150 4,050 2403

Gypsum, Broken . . . . . . . . . . . . . . . . . . . . . . 113 3,054 1810Crushed. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 4,698 2787

Halite (Rock Salt) Broken . . . . . . . . . . . . . . . 94 2,545 1506Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 3,915 2323

Hematite, Broken. . . . . . . . . . . . . . . . . . . . . . 201 5,430 3220Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 8,262 4902

Limonite, Broken. . . . . . . . . . . . . . . . . . . . . . 154 4,159 2467Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 6,399 3028

Limestone, Broken or Crushed . . . . . . . . . . . 97 2,625 1554Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 4,400 2611

Magnetite, Broken . . . . . . . . . . . . . . . . . . . . . 205 5,528 3,284Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 8,505 5046

Marble, Broken . . . . . . . . . . . . . . . . . . . . . . . 98 2,650 1570Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 4,308 2563

Marble Wet Excavated . . . . . . . . . . . . . . . . . . 140 3,780 2243Mica, Broken . . . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 4,860 2883

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191

APPROXIMATE WEIGHT OF MATERIALSWeight, Weight, Weight,

MATERIAL lbs./ft3 lbs./yd3 kg./m3

Mud, Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 2,916 1730Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 3,200 1906Dry Close . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110 2,160-32,970 1282-1762

Peat, Dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 675 400Moist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 1,350 801Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 1,890 1121

Phosphate Rock, Broken . . . . . . . . . . . . . . . . 110 2,970 1762Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.7 1,936 1148Plaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 1,431 848Porphyry, Broken . . . . . . . . . . . . . . . . . . . . . 103 2,790 1650Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 4,293 2547

Sandstone, Broken . . . . . . . . . . . . . . . . . . . . 94 2,550 1506Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 3,915 2323

Sand, Dry Loose . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Slightly Damp . . . . . . . . . . . . . . . . . . . . . . . 120 3,240 1922Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 3,500 2082Wet Packed . . . . . . . . . . . . . . . . . . . . . . . . . 130 3,510 2082

Sand and Gravel, Dry . . . . . . . . . . . . . . . . . . 108 2,916 1730Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3,375 2022

Shale, Broken . . . . . . . . . . . . . . . . . . . . . . . . 99 2,665 1586Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 4,500 2675

Slag, Broken . . . . . . . . . . . . . . . . . . . . . . . . . 110 2,970 1762Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 3,564 2114

Slag, Screenings . . . . . . . . . . . . . . . . . . . . . . 92 2495 1474Slag, Crushed (3⁄4") . . . . . . . . . . . . . . . . . . . . 74 1,998 1185Slag, Furnace, Granulated . . . . . . . . . . . . . . . 60 1,620 961Slate, Broken. . . . . . . . . . . . . . . . . . . . . . . . . 104 2,800 1666Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 4,535 2,691

Stone, Crushed . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Taconite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 4,050-5,400 2403-3204Talc, Broken . . . . . . . . . . . . . . . . . . . . . . . . . 109 2,931 1746Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 4,535 2691

Tar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.6 1,936 1148Trap Rock, Broken. . . . . . . . . . . . . . . . . . . . . 109 2,950 1746Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 4,870 2883

NOTE: The above weights may vary in accordance with moisture content, texture; etc.

MISCELLANEOUS USEFUL INFORMATIONArea of circle: Multiply square of diameter by .7854.Area of rectangle: Multiply length by breadth.Area of triangle: Multiply base by 1⁄2 perpendicular height.Area of ellipse: Multiply product of both diameters by .7854.Area of sector of circle: Multiply arc by 1⁄2 radius.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 by

1⁄2 slant height.Area of surface of sphere: Multiply diameter2 by 3.1416.Circumference of circle: Multiply diameter by 3.1416.Cubic inches in ball or sphere: Multiply cube of diameter by .5236.Cubic contents of cone or pyramid: Multiply area of base by 1⁄3 the altitude.Cubic contents of cylinder or pipe: Multiply area of one end by length.Cubic contents of wedge: Multiply area of rectangular base by 1⁄2 height.Diameter of circle: Multiply circumference by .31831.

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192

APPROXIMATE WEIGHTS IN POUNDS PER CUBIC YARDOF COMMON MINERAL AGGREGATES WITH VARIOUS

PERCENTAGES OF VOIDS(SPECIFIC GRAVITY OF 1 = APPROX. 1685 LBS.)

SpecificMaterial Gravity 25% 30% 35% 40% 45% 50%

2.8 3540 3300 3070 2830 2600 2360Trap 2.9 3660 3420 3180 2930 2690 2440Rock 3.0 3790 3540 3290 3030 2780 2530

3.1 3910 3650 3390 3130 2870 2610

Granite 2.6 3280 3060 2850 2630 2410 2190and 2.7 3410 3180 2960 2730 2500 2270

Limestone 2.8 3540 3300 3070 2830 2600 2360

2.4 3030 2830 2630 2420 2020 20202.5 3160 2950 2740 2520 2310 2100

Sandstone 2.6 3280 3060 2850 2630 2410 21902.7 3410 3180 2960 2730 2500 2270

2.0 2530 2360 2190 2020 1850 16802.1 2650 2470 2300 2120 1950 17702.2 2780 2590 2410 2220 2040 1850

Slag 2.3 2900 2710 2520 2320 2120 19402.4 3030 2830 2630 2420 2220 20202.5 3160 2950 2740 2520 2310 2100

GranulatedSlag 1.5 1890 1770 1640 1510 1390 1260

GravelSand 2.65 3350 3120 2900 2680 2450 2230

Percentage of Voids

NOTE: Most limestone, gravel and sand will absorb one percent or morewater by weight. Free water in moist sand approximates two percent,moderately wet 4 percent, and very wet seven percent.

DUMPING ANGLESAngles 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°

Page 193: Facts Figures Book

193

DECIMAL EQUIVALENTS OF FRACTIONS

Inch mm Inch mm

1⁄64 .39687 .015625 33⁄64 13.097 .5156251⁄32 .79375 .03125 17⁄32 13.494 .531253⁄64 1.1906 .046875 35⁄64 13.891 .5468751⁄16 1.5875 .0625 9⁄16 14.287 .5625

5⁄64 1.9844 .078125 37⁄64 14.684 .5781253⁄32 2.3812 .09375 19⁄32 15.081 .593757⁄64 2.7781 .109375 39⁄64 15.478 .6093751⁄8 3.1750 .125 5⁄8 15.875 .625

9⁄64 3.5719 .140625 41⁄64 16.272 .6406255⁄32 3.9687 .15625 21⁄32 16.669 .6562511⁄64 4.3656 .171875 43⁄64 17.066 .6718753⁄16 4.7625 .1875 11⁄16 17.462 .6875

13⁄64 5.1594 .203125 45⁄64 17.859 .7031257⁄32 5.5562 .21875 23⁄32 18.256 .7187515⁄64 5.931 .234375 47⁄64 18.653 .7343751⁄4 6.3500 .25 3⁄4 19.050 .75

17⁄64 6.7469 .265625 49⁄64 19.447 .7656259⁄32 7.1437 .28125 25⁄32 19.844 .7812519⁄64 7.5406 .296875 51⁄64 20.241 .7968755⁄16 7.9375 .3125 13⁄16 20.637 .8125

21⁄64 8.3344 .328125 53⁄64 21.034 .82812511⁄32 8.7312 .34375 27⁄32 21.431 .8437523⁄64 9.1281 .359375 55⁄64 21.828 .8593753⁄8 9.5250 .375 7⁄8 22.225 .875

25⁄64 9.9219 .390626 57⁄64 22.622 .89062513⁄32 10.319 .40625 29⁄32 23.019 .9062527⁄64 10.716 .421875 59⁄64 23.416 .9218757⁄16 11.112 .4375 15⁄16 23.812 .9375

29⁄64 11.509 .453125 61⁄64 24.209 .95312515⁄32 11.906 .46875 31⁄32 24.606 .9687531⁄64 12.303 .484375 63⁄64 25.003 .9843751⁄2 12.700 .5

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194

AREA AND CIRCUMFERENCE OF CIRCLES (INCHES)

Dia. Area Cir. Dia. Area Cir. Dia. Area Cir. Dia. Area Cir.

1⁄8 0.0123 .3926 10 78.54 31.41 30 706.86 94.24 65 3318.3 204.21⁄4 0.0491 .7854 101⁄2 86.59 32.98 31 754.76 97.38 66 3421.2 207.33⁄8 0.1104 1.178 11 95.03 34.55 32 804.24 100.5 67 3525.6 210.41⁄2 0.1963 1.570 111⁄2 103.86 36.12 33 855.30 103.6 68 3631.6 213.65⁄8 0.3067 1.963 12 113.09 37.69 34 907.92 106.8 69 3739.2 216.7

3⁄4 0.4417 2.356 121⁄2 122.71 39.27 35 962.11 109.9 70 3848.4 219.97⁄8 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

31⁄4 8.295 10.21 20 314.16 62.83 50 1963.5 157.0 85 5674.5 257.0

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

Page 195: Facts Figures Book

195

TRIGONOMETRIC FUNCTIONS

Angle Sin Cos Tan Angle Sin Cos Tan

0 0.000 1.000 0.000 46 0.719 0.695 1.041 0.017 0.999 0.017 47 0.731 0.682 1.072 0.035 0.999 0.035 48 0.743 0.699 1.113 0.052 0.999 0.052 49 0.755 0.656 1.154 0.070 0.998 0.070 50 0.766 0.643 1.19

5 0.087 0.996 0.087 51 0.777 0.629 1.236 0.105 0.995 0.105 52 0.788 0.616 1.287 0.112 0.993 0.123 53 0.799 0.602 1.338 0.139 0.990 0.141 54 0.809 0.588 1.389 0.156 0.988 0.158 55 0.819 0.574 1.4310 0.174 0.985 0.176 56 0.829 0.559 1.48

11 0.191 0.982 0.194 57 0.839 0.545 1.5412 0.208 0.978 0.213 58 0.848 0.530 1.6013 0.225 0.974 0.231 59 0.857 0.515 1.6614 0.242 0.970 0.249 60 0.866 0.500 1.7315 0.259 0.966 0.268 61 0.875 0.485 1.80

16 0.276 0.961 0.287 62 0.883 0.469 1.8817 0.292 0.956 0.306 63 0.891 0.454 1.9618 0.309 0.951 0.325 64 0.898 0.438 2.0519 0.326 0.946 0.344 65 0.906 0.423 2.1420 0.342 0.940 0.364 66 0.914 0.407 2.25

21 0.358 0.934 0.384 67 0.921 0.391 2.3622 0.375 0.927 0.404 68 0.927 0.375 2.4823 0.391 0.921 0.424 69 0.934 0.358 2.6124 0.407 0.914 0.445 70 0.940 0.342 2.7525 0.423 0.906 0.466 71 0.946 0.326 2.90

26 0.438 0.898 0.488 72 0.951 0.309 3.0827 0.454 0.891 0.510 73 0.956 0.292 3.2728 0.469 0.883 0.532 74 0.961 0.276 3.4929 0.485 0.875 0.554 75 0.966 0.259 3.7330 0.500 0.866 0.577 76 0.970 0.242 4.01

31 0.515 0.857 0.601 77 0.974 0.225 4.3332 0.530 0.848 0.625 78 0.978 0.208 4.7033 0.545 0.839 0.649 79 0.982 0.191 5.1434 0.559 0.829 0.675 80 0.985 0.174 5.6735 0.574 0.819 0.700 81 0.988 0.156 6.31

36 0.588 0.809 0.727 82 0.990 0.139 7.1237 0.602 0.799 0.754 83 0.993 0.122 8.1438 0.616 0.788 0.781 84 0.995 0.105 9.5139 0.629 0.777 0.810 85 0.996 0.087 11.4340 0.643 0.766 0.839 86 0.998 0.070 14.30

41 0.656 0.755 0.869 87 0.999 0.035 19.0842 0.669 0.743 0.900 88 0.999 0.035 28.6443 0.682 0.731 0.933 89 0.999 0.017 57.2844 0.695 0.719 0.966 90 1.000 0.000 Infinity45 0.707 0.707 1.000

Page 196: Facts Figures Book

196

THEORETICAL WEIGHTS OF STEEL PLATES

Wt. per Wt. per Wt. perSize Sq. Ft. Size Sq. Ft. Size Sq. Ft.

(Inches) (Lbs.) (Inches) (Lbs.) (Inches) (Lbs.)

3⁄16 7.65 9/16 22.95 11⁄4 51.001⁄4 10.20 5/8 25.50 13⁄8 56.105⁄16 12.75 3/4 30.60 11⁄2 61.203⁄8 15.30 7/8 35.70 15⁄8 66.307⁄16 17.85 1 40.80 13⁄4 71.401⁄2 20.40 11/8 45.90 2 81.60

Wt. per Wt. per Wt. perSize Sq. Ft. Size Sq. Ft. Size Sq. Ft.

(Inches) (Lbs.) (Inches) (Lbs.) (Inches) (Lbs.)

1 11.25 16 .0598 2.5002 10.625 17 .0538 2.2503 .2391 10.000 18 .0478 2.0004 .2242 9.375 19 .0418 1.7505 .2092 8.750 20 .0359 1.500

6 .1943 8.125 21 .0329 1.3757 .1793 7.500 22 .0299 1.2508 .1644 6.875 23 .0269 1.1259 .1494 6.250 24 .0239 1.00010 .1345 5.625 25 .0209 .875

11 .1196 5.000 26 .0179 .75012 .1046 4.375 27 .0164 .687513 .0897 3.750 28 .0149 .62514 .0747 3.125 29 .0135 .562515 .0673 2.812 30 .0120 .500

STANDARD STEEL SHEET GAUGES & WEIGHTS

NOTE: (1/4" Thick and Heavier Are Called Plates.)

To avoid errors specify decimal part of one inch or mention gaugenumber and the name of the gauge. Orders for a definite gaugeweight or gauge thickness will be subject to standard gauge weightor gauge thickness tolerance, applying equally plus and minus formthe ordered gauge weight or gauge thickness.

U.S. Standard Gauge—Iron and steel sheets. Note: U.S. StandardGauge was established by act of Congress in 1893, in which weightsper square foot were indicated by gauge number. The weight, notthickness, is determining factor when the material is ordered to thisgauge.

Page 197: Facts Figures Book

197

APPROXIMATE WEIGHTS PER LINEAL FOOTIN POUNDS OF STANDARD STEEL BARS

Dia. Dia.In. Rd. Hex. Sq. In. Rd. Hex. Sq.

1⁄16 .101 .012 .013 27⁄32 .190 2.10 2.423⁄32 .023 .026 .030 7⁄8 2.04 2.25 2.601⁄8 .042 .046 .053 29⁄32 2.19 2.42 2.795⁄32 .065 .072 .083 15⁄16 2.35 2.59 2.993⁄16 .094 .104 .120 31⁄32 2.51 2.7 3.197⁄32 .128 .141 .163 1 2.67 2.95 3.401⁄4 .167 .184 .212 11⁄16 3.01 3.32 3.849⁄32 .211 .233 .269 11⁄8 3.38 3.37 4.305⁄16 .261 .288 .332 13⁄16 3.77 4.15 4.8011⁄32 .316 .348 .402 11⁄4 4.17 4.60 5.313⁄8 .376 .414 .478 15⁄16 4.60 5.07 5.8613⁄32 .441 .486 .561 13⁄8 5.05 5.57 6.437⁄16 .511 .564 .651 17⁄16 5.52 6.09 7.0315⁄32 .587 .647 .747 11⁄2 6.01 6.63 7.651⁄2 .667 .736 .850 15⁄8 7.05 7.78 8.9817⁄32 .754 .831 .960 13⁄4 8.18 9.02 10.419⁄16 .845 .932 1.08 17⁄8 9.39 10.36 11.9519⁄32 .941 1.03 1.20 2 10.68 11.78 13.605⁄8 1.04 1.15 1.33 21⁄8 12.06 13.30 15.3521⁄32 1.15 1.27 1.46 21⁄4 13.52 14.91 17.2111⁄16 1.26 1.39 1.61 23⁄8 15.06 16.61 19.1823⁄32 1.38 1.52 1.76 21⁄2 16.69 18.40 21.253⁄4 1.50 1.66 1.91 23⁄4 20.20 22.27 25.7125⁄32 1.63 1.80 2.08 3 24.03 26.50 30.6013⁄16 1.76 1.94 2.24

WEIGHTS OF FLAT BARS AND PLATESTo find weight per foot of flat steel, multiply width in inches byfigure listed below:

APPROXIMATE WEIGHT OF VARIOUS METALSTo find weight of various metals, multiply contents in cubic inchesby the number shown; result will be approximate weight in pounds.

Thickness Thickness Thickness1⁄16". . . . . . . . . . . . . .2125 7⁄8" . . . . . . . . . . . . . 2.975 13⁄4" . . . . . . . . . . . 5.95011⁄8" . . . . . . . . . . . . .4250 15⁄16" . . . . . . . . . . . . 3.188 113⁄16" . . . . . . . . . . 6.1633⁄16". . . . . . . . . . . . . .6375 1" . . . . . . . . . . . . . 3.400 17⁄8" . . . . . . . . . . . 6.3751⁄4" . . . . . . . . . . . . . .8500 11⁄16" . . . . . . . . . . . . 3.613 115⁄16" . . . . . . . . . . 6.5885⁄16". . . . . . . . . . . . 1.0600 11⁄8" . . . . . . . . . . . . 3.825 2" . . . . . . . . . . . . . 6.8003⁄8" . . . . . . . . . . . . 1.2750 13⁄16" . . . . . . . . . . . . 4.038 21⁄8" . . . . . . . . . . . 7.2257⁄16". . . . . . . . . . . . 1.4880 11⁄4" . . . . . . . . . . . . 4.250 21⁄4" . . . . . . . . . . . 7.6501⁄2" . . . . . . . . . . . . 1.7000 115⁄16". . . . . . . . . . . 4.463 23⁄8" . . . . . . . . . . . 8.0759⁄16". . . . . . . . . . . . 1.9130 13⁄8" . . . . . . . . . . . . 4.675 21⁄2" . . . . . . . . . . . 8.5005⁄8" . . . . . . . . . . . . 2.1250 17⁄16" . . . . . . . . . . . 4.888 25⁄8" . . . . . . . . . . . 8.92511⁄16" . . . . . . . . . . . 2.3380 11⁄2" . . . . . . . . . . . . 5.100 23⁄4" . . . . . . . . . . . 9.3503⁄4" . . . . . . . . . . . . 2.5500 19⁄16" . . . . . . . . . . . 5.313 27⁄8" . . . . . . . . . . . 9.77513⁄16". . . . . . . . . . . . . . . . . . . . . . . 2.7630 15⁄8" . . . . . . . . . . . . 5.525 3" . . . . . . . . . . . . 10.200

111⁄16" . . . . . . . . . . . 5.738

Iron. . . . . . . . . . . . . . . . . . . .27777Steel . . . . . . . . . . . . . . . . . . .28332Copper . . . . . . . . . . . . . . . . .32118Brass . . . . . . . . . . . . . . . . . .31120

Lead . . . . . . . . . . . . . . . . . . .41015Zinc . . . . . . . . . . . . . . . . . . .25318Tin . . . . . . . . . . . . . . . . . . . .26562Aluminum. . . . . . . . . . . . . . .09375

Page 198: Facts Figures Book

198

STEEL WIRE GAUGE DATABrown & Steel WireSharpe or Gauge

Thickness *Wt. per American (WashburnGa. No. Inches Sq. Ft. Wire & Moren)

3 .259 10.567 .2294 .24374 .238 9.710 .2043 .22535 .220 8.976 .1819 .2070

6 .203 8.282 .1620 .19207 .180 7.344 .1443 .17708 .165 6.732 .1285 .16209 .148 6.038 .1144 .148310 .134 5.467 .1019 .1350

11 .120 4.896 .0907 .120512 .109 4.447 .0808 .105513 .095 3.876 .0720 .091514 .083 3.386 .0641 .080015 .072 2.938 .0571 .0720

16 .065 2.652 .0508 .062517 .058 2.366 .0453 .054018 .049 1.999 .0403 .047519 .042 1.714 .0359 .041020 .035 1.428 .0320 .0348

21 .032 1.306 .0285 .031722 .028 1.142 .0253 .028623 .025 1.020 .0226 .025824 .022 .898 .0201 .023025 .020 .816 .0179 .0204

26 .018 .734 .0159 .018127 .016 .653 .0142 .017328 .014 .571 .0126 .016229 .013 .530 .0113 .015030 .012 .490 .0100 .0140

NOTE: Birmingham or Stubs Gauge—Cold rolled strip, round edge flat wire,cold roll spring steel, seamless steel and stainless tubing and boilertubes.

*B.W. Gauge weights per sq. ft. are theoretical and based on steelweight of 40.8 lbs. per sq. ft. of 1" thickness; weight of hot rolledstrip is predicted by using this factor.

Steel Wire Gauge—(Washburn & Moen Gauge)—Round steel wire inblack annealed, bright basic, galvanized, tinned and copper coated.

Birmingham Wire Gaugeor Stubs Gauge

Page 199: Facts Figures Book

199

ROCKWELL-BRINELL CONVERSION TABLEBrinell Rockwell Brinell Rockwell

Numbers C Scale Numbers C Scale10 mm Ball Brale Penetrator 10 mm Ball Brale Penetrator

3000 kg Load 150 kg Load 3000 kg Load 150 kg Load

690 65 393 42673 64 382 41658 63 372 40645 62 362 39628 61 352 38614 60 342 37600 59 333 36587 58573 57 322 35560 56 313 34

305 33547 55 296 32534 54 290 31522 53 283 30509 52 276 29496 51 272 28484 50 265 27472 49 260 26460 48448 47 255 25437 46 248 24

245 23426 45 240 22415 44 235 21404 43 230 20

Coarse Fine Coarse FineSize NC NF Size NC NF

0 80 9⁄16 12 181 64 72 5⁄8 11 182 56 64 3⁄4 10 163 48 56 7⁄8 9 144 40 48 1 8 145 40 44 11⁄8 7 126 32 40 11⁄4 78 32 36 13⁄8 6

10 24 32 11⁄2 6 1212 24 28 13⁄4 51⁄4 20 28 2 41⁄25⁄16 18 24 21⁄4 41⁄23⁄8 16 24 21⁄2 47⁄16 14 20 23⁄4 41⁄2 13 20 3 4

Over 3

AMERICAN STANDARD COARSEAND FINE THREAD SERIES

Threads per inch Threads per inch

Page 200: Facts Figures Book

200

SPEED RATIOSSpeed ratios and groups from which speed change selection can be made.

Ratio of transmissionRevolutions per minute of faster shaftRevolutions per minute of slower shaft

=

Number of Teeth in Driver Gear & Sprocket

17 19 21 23 25 27 30 3319 1.12 1.00 0.91 0.83 0.76 0.70 0.64 0.5821 1.23 1.10 1.00 0.91 0.84 0.78 0.70 0.6523 1.35 1.21 1.10 1.00 0.92 0.85 0.78 0.7025 1.47 1.32 1.19 1.09 1.00 0.93 0.83 0.7627 1.59 1.42 1.28 1.17 1.08 1.00 0.90 0.8230 1.77 1.58 1.43 1.30 1.20 1.11 1.00 0.9133 1.94 1.74 1.57 1.43 1.32 1.22 1.19 1.0036 2.12 1.89 1.71 1.56 1.44 1.33 1.20 1.0940 2.35 2.10 1.90 1.74 1.60 1.48 1.33 1.2145 2.65 2.37 2.14 1.96 1.80 1.67 1.50 1.3650 2.94 2.63 2.38 2.18 2.00 1.85 1.67 1.5255 3.24 2.89 2.62 2.39 2.20 2.04 1.83 1.6760 3.53 3.16 2.86 2.61 2.40 2.22 2.00 1.8268 4.00 3.58 3.24 2.96 2.72 2.52 2.2775 4.41 3.95 3.57 3.26 3.00 2.7884 4.94 4.42 4.00 3.65 3.3690 5.30 4.74 4.28 3.91102 6.00 5.37 4.86

Number of Teeth in Driver Gear & Sprocket

36 40 45 50 55 60 68 7519 0.53 0.48 0.42 0.38 0.35 0.32 0.28 0.2521 0.58 0.53 0.47 0.42 0.38 0.35 0.31 0.2823 0.64 0.58 0.51 0.46 0.42 0.38 0.34 0.3125 0.70 0.63 0.56 0.50 0.46 0.42 0.37 0.3327 0.75 0.68 0.60 0.54 0.49 0.45 0.40 0.3630 0.83 0.75 0.67 0.60 0.55 0.50 0.4433 0.92 0.83 0.73 0.66 0.60 0.5536 1.00 0.90 0.80 0.72 0.6540 1.11 1.00 0.89 0.8045 1.25 1.13 1.0050 1.30 1.2555 1.53

GENERAL INFORMATION ON CHAINSThe chain drive has three elements; the driver sprocket, the drivensprocket, and the endless chain which transmits power form the firstto the second. The distance from center to center of adjacent chainpins is the chain pitch and also the sprocket pitch.

Chain speed, except for high speed RC and silent chains, should notexceed 500 ft. per min. Working load should be held under 1⁄6 theultimate strength for speeds up to 200 f.p.m., 1/10 where speed isbetween 200 and 300 f.p.m., and less if speed exceeds 300 f.p.m.

Chain speed, f.p.m. No. of teeth in sprocket x chain pitch (in.) x r.p.m.12

=

H.P. of drive Chain speed in f.p.m. x pull in pounds33,000

=

Number of Teeth in Driven Gear & Sprocket

Page 201: Facts Figures Book

201

CONVERSION OF THERMOMETER SCALE

°C. °F. °C. °F. °C. °F. °C. °F. °C. °F.-80 -112. 1 33.8 31 87.8 61 141.8 91 195.8-70 -94. 2 35.6 32 89.6 62 143.6 92 197.6-60 -76. 3 37.4 33 91.4 63 145.4 93 199.4-50 -58.0 4 39.2 34 93.2 64 147.2 94 201.2-45 -49.1 5 41.0 35 95.0 65 149.0 95 203.0-40 -40.0 6 42.8 36 96.8 66 150.8 96 204.8-35 -31.0 7 44.6 37 98.6 67 152.6 97 206.6-30 -22.0 8 46.4 38 100.4 68 154.4 98 208.4-25 -13.0 9 48.2 39 102.2 69 156.2 99 210.2-20 -4.0 10 50.0 40 104.0 70 158.0 100 212.0-19 -2.2 11 51.8 41 105.8 71 159.8 105 221.-18 -.4 12 53.6 42 107.6 72 161.6 110 230.-17 1.4 13 55.4 43 109.4 73 163.4 115 239.-16 3.2 14 57.2 44 111.2 74 165.2 120 248.-15 5.0 15 59.0 45 113.0 75 167.0 130 266.-14 6.8 16 60.8 46 114.8 76 168.8 140 284.-13 8.6 17 62.6 47 116.0 77 170.6 150 302.-12 10.4 18 64.4 48 118.4 78 172.4 160 320.-11 12.2 19 66.2 49 120.2 79 174.2 170 338.-10 14.0 20 68.0 50 122.0 80 176.0 180 356.-9 15.8 21 69.8 51 123.8 81 177.8 190 374.-8 17.6 22 71.6 52 125.6 82 179.6 200 392.-7 19.4 23 73.4 53 127.4 83 181.4 250 482.-6 21.2 24 75.2 54 129.2 84 183.2 300 572.-5 23.0 25 77.0 55 131.0 85 185.0 350 662.-4 24.8 26 78.8 56 132.8 86 186.8 400 752.-3 26.6 27 80.6 57 134.6 87 188.6 500 932.-2 28.4 28 82.4 58 136.4 88 190.4 600 1112.-1 30.2 29 84.2 59 138.2 89 192.2 700 1292.0 32.0 30 86.0 60 140.0 90 194.0 800 1472.

900 1652.1000 1832.

MISCELLANEOUS USEFUL INFORMATIONTo 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 ofwater when pressure in pounds per square inch is known, multiplypressure in pounds by 2.309 (2.309 Feet Water exerts pressure onone pound per square inch.)

Centigrade — Fahrenheit°C. = 5/9 (°F.—32) °F. = 9/5 °C. + 32

Page 202: Facts Figures Book

202

APPROX. SAFE LOAD FOR CHAINS AND WIRE ROPESUNDER DIFFERENT LOADING CONDITIONS

Single Leg Double LegAlloyChainSize

Inch mm Lbs. kg Lbs. kg Lbs. kg Lbs. kg1⁄4 6.35 3,250 1474 5,660 2563 4,600 2086 3,250 14743⁄8 9.52 6,600 2994 11,400 5171 9,300 4218 6,600 29941⁄2 12.7 11,250 5103 19,500 8845 15,900 7212 11,250 51035⁄8 15.9 16,500 7484 28,600 12973 23,300 10559 16,500 74843⁄4 19.0 23,000 10433 39,800 18053 32,500 14742 23,000 104337⁄8 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

11⁄4 31.7 57,500 26082 99,600 45178 81,300 36878 57,500 26082

Alloy Sling Chain ASTM A-391 Approx. Working Load Limits

The above Working Load Limits are based upon using chain having aworking load equal to that shown in column for single leg.

Courtesy of The Crosby Group

*Ton = 2,000 lbs. Courtesy Macwhyte Company

1 Sling Vertical 2 Legs 60° 2 Legs 45° 2 Legs 30°Single-PartRope Body

Size

Inch mm Tons* mt Tons* mt Tons* mt Tons* mt1⁄2 12.7 1.8 1.6 3.2 2.9 2.6 2.4 1.8 1.69⁄16 14.3 2.3 2.1 4.0 3.6 3.2 2.9 2.3 2.15⁄8 15.9 2.8 2.5 4.8 4.4 4.0 3.6 2.8 2.53⁄4 19.0 3.9 3.5 6.8 6.2 5.5 5.0 3.9 3.57⁄8 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

11⁄8 28.6 8.4 7.6 14.0 12.7 12.0 10.9 8.4 7.6

11⁄4 31.7 10.0 9.1 18.0 16.3 15.0 13.6 10.0 9.1

13⁄8 34.9 12.0 10.9 21.0 19.0 17.0 15.4 12.0 10.9

11⁄2 38.1 15.0 13.6 25.0 22.7 21.0 19.0 15.0 13.6

15⁄8 41.3 17.0 15.4 30.0 27.2 24.0 21.8 17.0 15.4

13⁄4 44.4 20.0 18.1 34.0 30.8 28.0 25.4 20.0 18.1

17⁄8 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

WIRE ROPE

RATED CAPACITY (Approx.)

Page 203: Facts Figures Book

203

AVERAGE SAFE CONCENTRATED LOADS ONWOODEN BEAMS—AVERAGE CONDITIONS

Concentrated Load = 1⁄2 of uniformly distributed load.

Span Load

Width Depth

Ft. meters In. mm In. mm Lbs. kg

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 1.829 6 152 6 152 1,398 634.1

6 152 8 203 2,490 1129

8 203 8 203 3,320 1506

8 203 10 254 5,184 2351

10 254 10 254 6,480 2939

10 254 12 305 9,330 4232

12 305 12 305 11,197 5097

8 2.438 6 152 6 152 1,050 476.3

6 152 8 203 1,866 846.4

8 203 8 203 2,488 1128

8 203 10 254 3,888 1763

10 254 10 254 4,860 2204

10 254 12 305 7,000 3175

12 305 12 305 8,400 3810

BeamDimension

Und

er id

eal c

onditio

ns th

e load

can

be increased

1 ⁄3

Page 204: Facts Figures Book

Lbs.

PerSq.

Yd.

12

34

56

78

910

2030

4050

601

0.3

0.6

0.9

1.2

1.5

1.8

2.1

2.3

2.6

2.9

5.9

8.8

11.7

14.7

17.6

20.6

1.2

1.8

2.3

2.9

3.5

4.1

4.7

5.3

5.9

11.7

17.6

23.5

29.3

35.2

30.9

1.8

2.6

3.5

4.4

5.3

6.2

7.0

7.9

8.8

17.6

26.4

35.2

44.0

52.8

41.2

2.3

3.5

4.7

5.9

7.0

8.2

9.4

10.6

11.7

23.5

35.2

46.9

58.7

70.4

51.5

2.9

4.4

5.9

7.3

8.8

10.3

11.7

13.2

14.7

29.3

44.0

58.7

73.3

88.0

61.8

3.5

5.3

7.0

8.8

10.6

12.3

14.1

15.8

17.6

35.2

52.8

70.4

88.0

105.6

72.1

4.1

6.2

8.2

10.3

12.3

14.4

16.4

18.5

20.5

41.1

61.5

82.1

102.7

123.2

82.3

4.7

7.0

9.4

11.7

14.1

16.4

18.8

21.1

23.5

46.9

70.4

93.9

117.3

140.8

92.6

5.3

7.9

10.6

13.2

15.8

18.5

21.1

23.8

26.4

52.8

79.2

105.6

132.0

158.4

102.9

5.9

8.8

11.7

14.7

17.6

20.5

23.5

26.4

29.3

58.7

88.0

117.3

146.7

176.0

205.9

11.7

17.6

23.5

29.3

35.2

41.1

46.9

52.8

58.7

117.3

176.0

234.7

293.3

352.0

308.8

17.6

26.4

35.2

44.0

52.8

61.6

70.4

79.2

88.0

176.0

264.0

352.0

440.0

527.9

4011.7

23.5

35.2

46.9

58.7

70.4

82.1

93.9

105.6

117.3

234.7

352.0

469.3

586.7

704.0

5014.7

29.3

44.0

58.7

73.3

88.0

102.7

117.3

132.0

146.7

293.3

440.0

586.7

733.3

880.0

6017.6

35.2

52.8

70.4

88.0

105.6

123.2

140.8

158.4

176.0

352.0

528.0

704.0

880.0

1056.0

7020.5

41.1

61.6

82.1

102.7

123.2

143.7

164.3

184.8

205.3

410.7

616.0

821.3

1026.7

1232.0

8023.5

46.9

70.4

93.9

117.3

140.8

164.3

187.7

211.2

234.7

469.3

704.0

938.7

1173.3

1408.0

9026.4

52.8

79.2

105.6

132.0

158.4

184.8

211.2

237.6

264.0

528.0

792.0

1056.0

1320.0

1584.0

100

29.3

58.7

88.0

117.3

146.7

176.0

205.3

234.7

264.0

293.3

586.7

880.0

1173.3

1466.7

1760.0

200

58.7

117.3

176.0

234.7

293.3

352.0

410.7

469.3

528.0

586.7

1173.3

1760.0

2346.7

2933.3

3520.0

300

88.0

176.0

264.0

352.0

440.0

528.0

616.0

704.0

792.0

880.0

1760.0

2640.0

3520.0

4400.0

5280.0

400

117.3

234.7

352.0

469.3

586.7

704.0

821.3

938.7

1056.0

1173.3

2346.7

3520.0

4693.3

5866.7

7040.0

500

146.7

293.3

440.0

586.7

733.3

880.0

1026.7

1173.3

1320.0

1466.7

2933.3

4400.0

5866.7

7333.3

8800.0

600

176.0

352.0

528.0

704.0

880.0

1056.0

1232.0

1408.0

1584.0

1760.0

3520.0

5280.0

7040.0

8800.0

10560.0

700

205.3

410.7

616.0

821.3

1026.7

1232.0

1437.3

1642.7

1848.0

2053.3

4106.7

6160.0

8213.3

10266.7

12320.0

800

234.7

469.3

704.0

938.7

1173.3

1408.0

1642.7

1877.3

2112.0

2346.7

4693.3

7040.0

9386.7

11733.3

14080.0

900

264.0

528.0

792.0

1056.0

1320.0

1584.0

1848.0

2112.0

2376.0

2640.0

5280.0

7920.0

10560.0

13200.0

15840.0

1000

293.3

586.7

880.0

1173.3

1466.7

1760.0

2053.3

2346.7

2640.0

2933.3

5866.7

8800.0

11733.3

14666.7

17600.0

204

TON

S O

F M

ATER

IAL

REQ

UIR

ED P

ER M

ILE

FOR

VAR

IOU

S W

IDTH

S AN

D P

OU

ND

S PE

R S

QU

ARE

YAR

D

NO

TE:F

ormula us

ed fo

rcalculation is as follo

ws:

w =

= 0.2933 RW

Where

w=

Weight of material in tons per mile

R=

Rate of application in lbs. per sq. yd.

W=

Width of application in feet

Data From

The Asphalt Institute

W __ 3()

5280

_____

3()

R____

2000()

WIDTH - FEET

Page 205: Facts Figures Book

205

APPR

OXI

MAT

E CU

BIC

YAR

DS

OF

AGG

REG

ATE

REQ

UIR

ED F

OR

ON

E M

ILE

OF

RO

AD A

TVA

RIO

US

WID

THS

AND

LO

OSE

DEP

THS—

(See Note)

NO

TE:1

6.30

cub

ic yards

—1" deep, 1' w

ide an

d 1 mile lo

ng. T

o ob

tain th

e am

ount of m

aterial req

uired for d

epth afte

r com

paction, in

crease th

e ab

ove fig

ures 15%

to30

% dep

ending

on the type

and

grada

tion of m

aterial.

Width of

Sq. Y

ds.

Roa

dPe

r(Ft.)

Mile

12

34

56

78

910

158

716

3349

6581

9811

413

014

716

38

4693

130

261

391

521

652

782

913

1043

1173

1304

952

8014

729

344

058

773

388

010

2711

7313

2014

6710

5867

163

326

489

652

815

978

1141

1304

1467

1630

1270

4019

639

158

778

297

811

7313

6915

6517

6019

5614

8213

228

456

685

912

1141

1369

1597

1825

2054

2282

1588

0024

448

973

397

712

2214

6717

1119

5522

0024

4516

9387

261

521

782

1042

1304

1564

1827

2086

2347

2608

1810

560

293

587

880

1173

1467

1760

2053

2347

2641

2933

2011

733

326

652

978

1304

1630

1956

2281

2607

2933

3259

2212

907

358

717

1076

1434

1793

2152

2510

2868

3228

3586

2414

080

391

782

1173

1564

1956

2347

2738

3128

3521

3912

2615

253

424

847

1271

1694

2119

2543

2966

3388

3815

4238

2816

427

456

913

1369

1824

2282

2738

3194

3684

4108

4564

3017

600

489

879

1467

1956

2444

2933

3422

3911

4440

4889

4023

467

652

1304

1956

2607

3259

3911

4563

5215

5867

6519

LOOSE

DEP

TH (Inc

hes)

Page 206: Facts Figures Book

Den

sity

(Lbs

. per

Cu. Y

d)1

23

45

67

89

1012

1500

41.7

83.3

125.0

166.7

208.3

250.0

291.7

333.3

375.0

416.6

500.0

1600

44.4

88.9

133.3

177.8

222.2

266.7

311.0

355.5

400.0

444.4

533.3

1700

47.2

94.5

141.6

188.9

236.1

283.3

330.4

377.8

425.0

472.2

566.7

1800

50.0

100.0

150.0

200.0

250.0

300.0

350.0

400.0

450.0

500.0

600.0

1900

52.8

105.5

158.3

211.1

263.9

316.7

369.4

422.2

475.0

527.8

633.3

2000

55.6

111.1

166.7

222.2

277.8

333.3

388.9

444.4

500.0

555.6

666.7

2100

58.3

116.7

175.0

233.3

291.7

350.0

408.3

466.7

525.5

583.4

733.3

2200

61.1

122.2

183.3

244.4

305.6

366.7

427.8

488.9

550.0

611.1

733.3

2300

63.9

127.8

191.7

255.5

319.5

383.3

447.2

511.1

575.0

638.9

766.6

2400

66.7

133.3

200.0

266.7

333.3

400.0

466.7

533.3

600.0

666.7

800.0

2500

69.4

138.9

208.3

277.8

347.2

416.7

486.1

555.5

625.0

694.4

833.3

2600

72.2

144.4

216.7

288.9

361.1

433.3

505.6

577.8

650.0

722.2

866.7

2700

75.0

150.0

225.0

300.0

375.0

450.0

525.0

600.0

675.0

750.0

900.0

2800

77.8

155.5

233.3

311.1

388.9

466.7

544.4

622.2

700.0

777.8

933.3

2900

80.6

161.1

241.7

322.2

402.8

483.3

563.9

644.4

725.0

805.6

966.7

3000

83.3

166.7

250.0

333.3

416.7

500.0

563.3

666.7

750.0

833.3

1000

.0

3100

86.1

172.2

258.3

344.4

430.6

516.7

602.8

688.9

775.0

861.2

1033

.332

0088

.917

7.8

266.7

355.5

444.5

533.3

622.2

711.1

800.0

888.9

1066

.733

0091

.718

3.3

275.0

366.7

458.3

550.0

641.7

733.3

825.0

944.4

1133

.334

0094

.418

8.9

283.3

377.8

472.2

566.7

661.1

755.5

850.0

944.4

1133

.3

3500

97.2

194.4

291.7

388.9

486.1

583.3

680.6

777.8

875.0

972.2

1166

.736

0010

0.0

200.0

300.0

400.0

500.0

600.0

700.0

800.0

900.0

1000

.012

00.0

3700

102.8

205.5

308.3

411.1

513.9

626.7

719.4

822.2

925.0

1027

.812

33.3

206

APPR

OXI

MAT

E W

EIG

HT

IN P

OU

ND

S PE

R S

QU

ARE

YAR

D O

F AG

GR

EGAT

ES O

F V

ARYI

NG

DEN

SITI

ES A

T VA

RIO

US

DEP

THS

DEP

TH (Inc

hes)

Page 207: Facts Figures Book

207

Area

(Squ

are

Feet)

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

10.03

.05

.06

.08

.09

.11

.13

.14

.15

.17

.19

20.06

.09

.12

.16

.19

,22

.25

.28

.31

.34

.37

30.09

.14

.19

.23

.28

.33

.37

.42

.46

.41

.56

40.12

.19

.25

.31

.37

.43

.50

.56

.62

.68

.74

50.15

.23

.31

.39

.46

.54

.62

.70

.77

.85

.93

60.19

.28

.37

.46

.56

.65

.74

.83

.93

1.02

1.11

70.22

.32

.43

.54

.65

.76

.87

.97

1.08

1.19

1.30

80.25

.37

.49

.62

.74

.87

1.00

1.11

1.24

1.36

1.67

90.28

.42

.56

.70

.84

.97

1.11

1.25

1.39

1.53

1.67

100

.31

.46

.62

.78

.93

1.08

1.24

1.39

1.55

1.70

1.85

200

.62

.93

1.23

1.54

1.85

2.16

2.47

2.78

3.09

3.40

3.70

300

.93

1.39

1.85

2.32

2.78

3.24

3.70

4.17

4.63

5.10

5.56

400

1.23

1.83

2.47

3.10

3.70

4.32

4.94

5.56

6.17

6.79

7.41

500

1.54

2.32

3.09

3.86

4.63

5.40

6.17

7.00

7.72

8.49

9.26

600

1.85

2.78

3.70

4.63

5.56

6.48

7.41

8.33

9.26

10.19

11.11

700

2.16

3.24

4.32

5.40

6.48

7.56

8.64

9.72

10.80

11.88

12.96

800

2.47

3.70

4.94

6.20

7.41

8.64

9.88

11.11

12.35

13.58

14.82

900

2.78

4.17

5.56

6.95

8.33

9.72

11.11

12.50

13.89

15.28

16.67

1000

3.09

4.63

6.17

7.72

9.26

10.80

12.35

13.89

15.43

16.98

18.52

APPROXIMATE CUBIC YARDS OF CONCRETE IN SLABS OF VARIOUS AREAS AND THICKNESS

THICKN

ESS OF SL

ABS (Inc

hes)

NO

TE:T

his table may be us

ed to

estim

ate the cu

bic co

nten

t of s

labs

of g

reater th

ickn

ess an

d area th

an th

ose sh

own. Examples: T

o fin

d the cu

bic co

nten

t of a

slab of

1000

sq. ft. a

rea an

d 8" th

ickn

ess, add

the fig

ures given

und

er 6" a

nd 2" for 100

0 sq

. ft. To

find

the cu

bic co

nten

t of a

slab 6" th

ickn

ess an

d 15

00 sq. ft. a

rea,

add the fig

ures given

for 1

000 an

d 50

0 sq

. ft. un

der 6

" thickne

ss.

Page 208: Facts Figures Book

208

DEFINITIONS AND TERMS

Admixtures—Substances, not normally a part of pavingmaterials or mixtures, added to them to modify their prop-erties.

Agglomeration—Gathering into a ball or mass.

Aggregates—In the case of materials for construction,essentially inert materials which when bound together intoa conglomerated mass by a matrix form asphalt, concrete,mortar or plaster; crushed rock or gravel screened to sizefor use on road surfaces.

Ballast—Broken stone or gravel used in stabilizing a roadbed or making concrete.

Bank Gravel—Gravel found in natural deposits, usuallymore or less intermixed with fine material, such as sand orclay, or combinations thereof; gravelly clay, gravelly sand,clayey gravel, and sandy gravel, indicate the varying pro-portions of the materials in the mixture.

Base—Foundation for pavement.

Beneficiation—Improvement of the chemical or physicalproperties of a material or intermediate product by theremoval of undesirable components or impurities.

Binder Course—The course, in sheet asphalt and bitu-minous concrete pavements, placed between base andsurface courses.

Binder Soil—Material consisting primarily of fine soil par-ticles (fine sand, silt, true clay and colloids); good bindingproperties; 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 pave-ment caused by excessive longitudinal pressure.

Bog—Wet spongy ground, sometimes filled with decayedvegetable matter.

Boulders—Detrital material greater than about 8" indiameter.

Construction Joint—Vertical or notched plane of sepa-ration in pavement.

Page 209: Facts Figures Book

209

DEFINITIONS AND TERMS (Continued)

Contraction Joint—Joint of either full depth or weakenedplane type, designed to establish position of any crackcaused by contraction, while providing no space forexpansion of pavement beyond original length.

Corrugations—Regular transverse undulation in surfaceof pavement consisting of alternate valleys and crests.

Cracks—Approximately vertical cleavage due to naturalcauses or traffic action.

Crazing—Pattern cracking extending only through sur-face layer, a result of more drying shrinkage in surfacethan interior of plastic concrete.

“D” Lines—Disintegration characterized by successiveformation of series of fine cracks at rather close intervalsparalleling edges, joints and cracks, and usually curvingacross slab corners. Initial cracks forming very close toslab edge and additional cracks progressively developing,ordinarily filled with calcareous deposit.

Dense and Open Graded Aggregates—Dense appliesto graded mineral aggregate containing sufficient dust ormineral filler to reduce all void spaces in compactedaggregate to exceedingly small diameters approximatingsize of voids in filler itself, may be either coarse or finegraded; open applies to graded mineral aggregate con-taining no mineral filler or so little that void spaces incompacted aggregate are relatively large.

Dewater—To remove water by pumping, drainage, orevaporation, or a dewatering screw.

Disintegration—Deterioration into small fragments fromany cause.

Distortion—Any deviation of pavement surface from orig-inal shape.

Expansion Joint—Joint permitting pavement to expandin length.

Faulting—Differential vertical displacement of slabs adja-cent to joint or crack.

Flume—An open conduit of wood, concrete or metal.

Gradation—Sieve analysis of aggregates, a general termto describe the aggregate composition of a mix.

Page 210: Facts Figures Book

210

DEFINITIONS AND TERMS (Continued)

Gradation Aggregates—Percentages of aggregate inquestion which fall into specified size limits. Purpose ofgrading aggregates is to have balanced gradation ofaggregate so that voids between sizes are progressivelyfilled with smaller particles until voids are negligible.Resulting mix reaches highest mechanical stability with-out binder.

Granites—Crystalline, even-grained rocks consistingessentially of feldspar and quartz with smaller amounts ofmica and other ferro-magnesian minerals.

Gravel—Granular, pebbly material (usually coarser than1/4" in diameter) resulting from natural disintegration ofrock; usually found intermixed with fine sands and clay;can be identified as bank, river or pea gravel; roundedcharacter of some imparted by stream action.

Gravity—The force that tends to pull bodies towards thecenter of mass, to give bodies weight.

Grit—A coarse sand formed mostly of angular quartzgrains.

Gumbo—Soil of finely divided clays of varying capillarity.

“Hollows”—Deficiencies in certain fractions of a pitrungravel.

Igneous—Natural rock composed of solidified moltenmaterial.

Lime Rock—Natural material essentially calcium carbon-ate with varying percentages of silica; hardens uponexposure to elements; some varieties provide excellentroad material.

Limestone—Natural rock of sedimentary origin com-posed principally of calcium carbonate or calcium andmagnesium carbonates in either its original chemical orfragmental, or recrystallized form.

Loam—Soil which breaks up easily, usually consisting ofsand, clay, and organic material.

Loess—An unstratified deposit of yellow-brown loam.

Manufactured Sand—Not natural occurring sand, -3⁄8"material made by crushing +3⁄8" material.Mesh—The number of openings per lineal inch in wirescreen.

Page 211: Facts Figures Book

211

DEFINITIONS AND TERMS (Continued)

Metamorphic Rock—Pre-existing rock altered to such anextent as to be classed separately. One of the three basicrock formations, including igneous and sedimentary.

Micron—A unit of length; one thousandth of a millimeter.

Mineral Dust or Filler—Very finely divided mineral prod-uct, great bulk of which will pass No. 200 sieve.Pulverized limestone is most commonly manufacturedfiller; other stone dust, silica, hydrated lime and certainnatural deposits of finely divided mineral matter are alsoused.

Muck—Moist or wet decaying vegetable matter or peat.

Natural Cement—Product obtained by finely pulverizingcalcined argillaceous limestone, to which not to exceed 5percent of nondeleterious materials may be added subse-quent to calcination. Temperature of calcination shall beno higher than necessary to drive off carbonic acid gas.

Ore—Any material containing valuable metallic matterwhich is mined or worked.

Outcropping—A stratum of rock or other material whichbreaks surface of ground.

Overburden—Soil mantle, waste, or similar matter founddirectly above deposit of rock or sand-gravel.

Paving Aggregate—Vary greatly as to grade, quality,type, and composition; general types suitable for bitumi-nous construction can be classified as: Crushed Stone,Gravel, Sand, Slag, Shell, Mineral Dust.

Pebbles—Rock fragments of small or moderate sizewhich have been more or less rounded by erosionalprocesses.

Pitrun—Natural gravel deposits; may contain some sand,clay or silt.

Portland Cement—Product obtained by pulverizingclinker consisting essentially of hydraulic calcium silicatesto which no additions have been made subsequent to cal-cination other than water or untreated calcium sulfate,except that additions not to exceed 1 percent of othermaterials may be interground with clinker at option ofmanufacturer, provided such materials have been shownto be not harmful.

Page 212: Facts Figures Book

212

DEFINITIONS AND TERMS (Continued)

Riprap—Riprap as used for facing dams, canals, andwaterways is normally a coarse, grade material. Typicalgeneral specifications would call for a minimum 160 lb./ft3

(2563 kg/m3) stone, free of cracks and seams with nosand, clay, dirt, etc.

Sand—Standard classification of soil or granular materialpassing the 3⁄8" (9.52mm) sieve and almost entirely pass-ing the No. 4 (4.76mm) sieve and predominantly retainedon the No. 200 (74 micron) sieve.

Sand Clay (Road Surface)—Surface of sand and claymixture in which the two materials have been blended sotheir opposite qualities tend to maintain a condition of sta-bility under varying moisture content.

Sand, Manufactured—Not natural occurring sand, -3⁄8"material made by crushing +3⁄8" material.

Sandstone—Essentially rounded grains of quartz, with orwithout interstitial cementing materials, with the largergrains tending to be more perfectly rounded than thesmaller ones. The fracture takes place usually in thecement leaving the grains outstanding.

Scalp Rock—Rock passed over a screen and rejected—waste rock.

Screenings—Broken rock, including dust, or size that willpass through 1/2" to 3/4" screen, depending upon char-acter of stone.

Sedimentary—Rocks formed by the deposit of sediment.

Settling Rock—An enlargement to permit the settlementof debris carried in suspension, usually provided withmeans of ejecting the material collected.

Shale—Material composed essentially of silica and alu-mina with a more or less thinly laminated structureimparted by natural stratification of extremely fine sedi-ments together with pressure.

Shell Aggregate—Applies to oyster, clam shells, etc.,used for road surfacing material; shells are crushed tosize but generally must be blended with other fine sandsto produce specification gradation.

Sieve—Test screens with square openings.

Page 213: Facts Figures Book

213

DEFINITIONS AND TERMS (Continued)

Slag—By-product of blast furnace; usually makes goodpaving material, can be crushed into most any gradation;most are quite porous.

Slates—Rocks, normally clayey in composition, in whichpressure has produced very perfect cleavage; readily splitinto thin, smooth, tough plates.

Slope Angle—The angle with the horizontal at which aparticular material will stand indefinintely without move-ment.

Specific Gravity—The ratio of the mass of a unit volumeof a material at a stated temperature to the mass of thesame volume of a gas-free distilled water at the sametemperature.

Stone—Any natural rock deposit or formation of igneous.sedimentary and/or metamorphic origin, either in originalor altered form.

Stone-Sand—Refers to product (usually less than 1/2" indiameter) produced by crushing of rock; usually highlyprocessed, should not be confused with screenings.

Stratum—A sheet-like mass of sedimentary rock or earthof one kind, usually in layers between bed of other kinds.

Sub-Grade—Native foundation on which is placed roadmaterial or artificial foundation, in case latter is provided.

Sub-Soil—Bed or earth immediately beneath surface soil.

Tailings—Stones which, after going through crusher, donot pass through the largest openings on the screen.

Top-Soil (Road Surface)—A variety of surfacing usedprincipally in southeastern states, being stripping of cer-tain top-soils containing natural sand-clay mixture. Whenplaced on road surface, wetted and puddled under traffic,it develops considerable stability.

Trap—Includes dark-colored, fine-grained, dense igneousrocks composed of ferro-magnesian minerals, basicfeldspars, and little or no quartz; ordinary commercial vari-ety is basalt, diabase, or gabbro.

Viscosity—The measure of the ability of a liquid or solidto resist flow. A liquid with high viscosity will resist flowmore readily than a liquid with low viscosity.

Page 214: Facts Figures Book

214

DEFINITIONS AND TERMS (Continued)

Voids—Spaces between grains of sand, gravel or soil thatare occupied by water or air or both.

Weir—A structure for diverting or measuring the flow ofwater.

Page 215: Facts Figures Book

215

NOTES:

Page 216: Facts Figures Book

216

NOTES: