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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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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
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worldwideintermsofbothamount
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USGS
FIGURENO.1
6
5
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2
1
4
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
5
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
6
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
7
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
8
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.
9
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.
10
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.
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.
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.
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
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
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
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.
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.
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
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
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
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
22
JAW CRUSHING PLANTS
Rubber Tire Mounted
Track Mounted
Stationary
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
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
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.
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
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
)*
** **
28
HSI PLANTS
Track mounted
Rubber tire mounted Andreas style
Rubber tire mounted New Holland style
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.
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
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.
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"
33
CONE CRUSHERS
Track mounted
Rubber tire mounted Kodiak Plus
Rubber tire mounted LS
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).
35
KODIAK PLUS ANDLS CONE CRUSHERS
KODIAK 300+ CONE
1400 LS Cone
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.
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.
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.
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.
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)
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)
42
NOTES:
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.
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.
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.)
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)
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
48
NOTES:
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.
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.
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)
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)
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)
54
NOTES:
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.
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.
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
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
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
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
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
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
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
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
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
****
****
****
****
****
****
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
****
****
****
****
****
****
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
**
****
****
**
****
****
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
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"
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
****
**
**
**
**
**
**
**
**
**
71
VERTICAL SHAFT IMPACT
Rubber tire mounted
Stationary Plant
Bare unit
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
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.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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.
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.
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
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
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.
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
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).
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
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
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
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
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)
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.
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
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
(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
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.
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.
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
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)
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.
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
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
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
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
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
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.
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
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.
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.
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
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
• 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
• 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
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.
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
127
MAX
IMU
MM
AXIM
UM
MAX
IMU
MFI
NE
STAN
DAR
DLI
GH
TM
EDIU
MH
EAVY
MAT
ERIA
LO
PEN
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SPEE
DST
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SCAL
PIN
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aSI
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RPM
b(I
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(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
$$“Q
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rry
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rX
XX
36grizzly ba
r80
07/16
12$$
$$
a- c
ontrolled feed
drop he
ight re
quire
d, <24
" drop for m
aterial s
ize to 12", <
18" d
rop for m
aterial s
ize to 36"
b- s
lower spe
ed m
ust b
e us
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ith m
axim
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ith highe
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r design d
- 8x2
0 screen
ope
rates at 15 de
grees e
- single sh
aft w
ith 4 bearin
gs, fixed
strok
e f
- 5" m
ax ope
ning
on 5x
14, 5
x16, 6x1
6 screen
s; 4" m
ax ope
ning
on 6x
20, 7
x20, 8x2
0 g
- maxim
um strok
eis 5/8" to 3/4" dep
ending
on screen
spe
ed
SCR
EEN
MAT
RIX
128
MAX
IMU
MM
AXIM
UM
MAX
IMU
MFI
NE
STAN
DAR
DLI
GH
TM
EDIU
MH
EAVY
MAT
ERIA
LO
PEN
ING
SPEE
DST
RO
KESL
OPE
MO
DEL
SCR
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SCR
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SCAL
PIN
GSC
ALPI
NG
SCAL
PIN
GSI
ZE (I
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aSI
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RPM
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(DEG
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ON
OM
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KOLB
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SCR
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S71
Stand
ard
Inclined
XX
52.5
1100
-150
01/4
10-15
$72
Desan
der
Inclined
XX
52.5
1100
-130
03/16
25-35
$72
Griz
zly
Inclined
X10
3c10
00-120
05/16
10-15
$
PIO
NEE
RSC
REE
NS
High
Inclined
XX
63
950-10
503/16
18-22
$$Stan
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XX
X12
485
0-95
03/8
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$$Mesab
iStan
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XX
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6c95
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10-12
$$$
Mesab
iHeavy
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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
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
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
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.
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.
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
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
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
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
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
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
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
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
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
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
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
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
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.
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
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
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
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
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
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
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
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:
154
CON
VEYO
R B
ELT
CAR
RYIN
G C
APAC
ITY
AT V
ARIO
US
SPEE
DS
NO
TE: *
Capa
city
is b
ased
on
mat
eria
l wei
ghin
g 10
0 lb
./cu
. ft.
with
37.
5 de
gree
ang
le o
f rep
ose,
3-r
oll,
35
degr
ee id
lers
and
no
skir
t boa
rds.
*Cap
acity
is th
eore
tical
bas
ed o
n a
full
cros
s se
ctio
n. T
o us
e fo
r con
veyo
r siz
ing,
use
75%
-80%
of t
he c
apac
ity li
sted
abo
ve.
Belt
Capa
city in
Ton
s Pe
r Hou
r*Width
Belt Sp
eeds
F.P.M.
Inch
es10
015
020
025
030
035
040
045
050
055
060
0
1869
103
138
172
207
241
276
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
155
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
156
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.
157
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.
158
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
159
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.
160
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.
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.
162
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.
163
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.
164
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
165
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
166
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%
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.
168
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.
169
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.
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)
171
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
172
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:
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
‡‡
‡‡‡
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.
‡��
**
*�
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
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
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.
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
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"
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"
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
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
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
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
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
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
{
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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
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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.{
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
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.
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°
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
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
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
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.
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
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
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
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
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
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.)
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
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
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)
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)
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.
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.
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.
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.
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.
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.
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.
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.
215
NOTES:
216
NOTES: