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KOLBERG-PIONEER, INC. and JCI, Astec companies (Nasdaq: ASTE) are a world wide and industry leaders for bulk material handling and processing equipment manufacturing; Conveyors, Screening Plants, Pugmill Plants, Sand and Aggregate Washing/Classifying Systems and all types of Portable and Stationary Rock Crushers for the aggregate, recycle and remediation industries under the PIONEER, and trade names of KOLBERG, JCI . Kolberg-Pioneer, Inc. and JCI have made every effort to present the information contained in this booklet accurately. However, the information should be a general guide and Kolberg-Pioneer, Inc. and JCI do not represent the information as exact under all conditions. Because of widely varying field conditions and characteristics of material processed, information herein covering machine capacities and gradations produced are estimated only. Products of Kolberg-Pioneer, Inc. and JCI are subject to the provisions of their Standard Warranty. All specifications are subject to change without notice.
Emblems , , Magna Cone, Spec-Select, Kodiak, Combo, Spokane, Has All The Pieces, KOLBERG-PIONEER and JCI are trademarks of and
Printed in U.S.A.
FORWARD
Aggregate production is based on mathematical relationshipsvolumes, lengths, widths, heights and speeds. Because of widely varying field conditions and characteristics of material processed, information herein relating to machine capacities and gradations produced are estimates only. Much of this data of special interest to producers and their employees has been included in this valuable Facts and Figures booklet. At the same time, we take this opportunity to acquaint you with our ever-broadening line of equipment for aggregate producers that includes; Conveyors, Screening Plants (Horizontal, Incline, Multi-Angle, Direct Feed, Portable), Sand and Aggregate Washing/Classifying Systems, all types of Rock Crushers (Jaw, Cone, Impact) in Portable, Stationary and Track Mounted Models and Pugmill Plants under the trade names of
and
iron gold
copper
Courtesy of
USGS
FIGURE NO. 1
sillimenite antimony zirconium niobium peat feldspar tungsten sulphur barite phosphate vanadium diamond graphite silver mica platinum cobalt zinc fluorspar clays diatomite manganese bentonite kaoline molybdenum asbestos chromite nickel uranium gypsum lead titanium potassium salt boron soda talc salt tin magnesite bauxite
TABLE OF CONTENTS
Angle of Repose/Surcharge . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Autogenous Crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 75 Belt Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Blade Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-97 Capacity Belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Cone crushers Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 42 LS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Magna Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-59 Feeders Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Reciprocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Vibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Horizontal Shaft Impactor (HSI) Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Jaws Legendary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Vanguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Roll Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-67 Screen Plants, portable . . . . . . . . . . . . . . . . . . . . . . . . . 164-166 Screens JCI Formula (using additional factors) . . . . . . . . . . . 139-158 KolbergPioneer Formula (VSMA factors) . . . . . . . . 79, 161 Stockpile Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Telescoping stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . . . . 69
Classifying
Controls (Spec-Select I, II and III) . . . . . . . . . . . . . . . . . 115-116 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Pipes, Velocity Flow and Friction Loss . . . . . . . . . . . . . . . . . . 111 Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Weir Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 205 Coarse Material Washing . . . . . . . . . . . . . . . . . . . . . . . 91, 94-95 Combo (Multi-Slope) Screens . . . . . . . . . . . . . . . . . . . . 136-138
Cone Crushers
Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 34-47 LS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 48-55 Magna Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-59 Conveyors, Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Belt speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177, 181 4 Recommended by material . . . . . . . . . . . . . . . . . . . . . . . 177
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Capacity, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171-172 Horse Power requirements . . . . . . . . . . . . . . . . . . . . . . 179-180 Idler classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Incline bulk materials, recommended. . . . . . . . . . . . . . . . . . . 168 Models, sizes and selections . . . . . . . . . . . . . . . . . . . . . 182-190
Crushers
Cones Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 34-47 LS Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 48-56 Magna Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-59 Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-78 Horizontal Shaft Impactors (HSI) Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-27 Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-67 Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . 68-75
Crusher notes
Kodiak and LS Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Magna Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Vertical Shaft Impactor (VSI) . . . . . . . . . . . . . . . . . . . . . . . 68, 75
Data
Angle of repose surcharge . . . . . . . . . . . . . . . . . . . . . . . . . 174 Belt carrying capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Belt speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Elevation, conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . 171-172 Horse Power requirements . . . . . . . . . . . . . . . . . . . . . . 179-180 Idler classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Incline, bulk materials, recommended . . . . . . . . . . . . . . . . . . 168 Stockpile Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Telescoping stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Weights, common materials. . . . . . . . . . . . . . . . . . . . . . . . . . 214 Weir flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 205 Wire mesh for vibrating screens. . . . . . . . . . . . . . . . . . . . . . . . 80 Data, Industry Terms and Definitions . . . . . . . . . . . . . . 195-231 Dredge, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Electric motors and wiring . . . . . . . . . . . . . . . . . . . . . . . 198-201 Generator sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Pipes, velocity flow and friction loss. . . . . . . . . . . . . . . . 203-204 Railroad ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Riprap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126, 206-209 Weights and measurers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Definitions and Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 232-238
Feeder Capacities
Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Reciprocating plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Vibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Fine Material Washing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-101 FM (Fineness Modulus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 General Information on the Aggregate Industry . . . . . . 3, 8-11
Gradations
Aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15, 84-85 ASTM C-33, C-144 . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 88-89 Gravel, typical deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-78 Horizontal Shaft Impactors (HSI) Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Jaw Crushers, Peak to Peak (CSS) . . . . . . . . . . . . . . . . . . . . . 23 Kodiak series cone crushers . . . . . . . . . . . . . . . . . 36-37, 42-43 Limestone, typical quarry run . . . . . . . . . . . . . . . . . . . . . . . . . . 15 LS series cone crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-49 Magna cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-58 Roll crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61 Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . 70-74 Washing, classifying . . . . . . . . . . . . . . . . . . . . . . . . . . . 105, 113 Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Incline screens
JCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-135 Pioneer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-81 Jaw Crushers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-27 Kodiak Cone crusher series . . . . . . . . . . . . . . . . . . . . 32, 34-47 Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-93 LS Cone crusher series . . . . . . . . . . . . . . . . . . . . . . . . 32, 48-56 Magna Cone crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-59 Notes (blank pages) . . . . . . . . . . 87, 117, 127, 133, 159, 167,
Peak to Peak Jaw crusher settings . . . . . . . . . . . . . . . . . 25, 27 Pugmills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192-193 Roll crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-67 Screening and Washing Plants . . . . . . . . . . . . . . . . . . . 118-119 Screens, calculating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Screens, JCI Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Screens, Kolberg Introduction . . . . . . . . . . . . . . . . . . . . . . . . 160 Screens, Types Combo (Multi-Slope) JCI . . . . . . . . . . . . . . . . . . . . . . . . 136-138 Formula - JCI (with new factors) . . . . . . . . . . . . . . . . . . 139-158 Formula - Kolberg-Pioneer (standard VSMA factors) . . . 79, 161 Horizontal - JCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-132 Incline - JCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-135 Multi-Slope (Combo) JCI . . . . . . . . . . . . . . . . . . . . . . . . 136-138 Pioneer Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Portable plants - Kolberg KDS models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Models 241, 271, 291 . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Model 291, 391, 391-T. . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Sieve sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 80, 85-86, 88-89 Units - Kolberg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162-163 Screens, wire mesh (cloth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 SE (Sand Equivalent test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Sieve sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 Spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126, 206-209
Stockpile
Angle of Repose/Surcharge . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Telescoping Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 187-188 Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . 232-238
Rapid field investigations for possible sources of minerals have been made very simple and relatively inexpensive by the use of portable seismic instruments and earth resistivity meters. The latter are especially effective in locating sand, gravel and ground water by measuring the inherent electrical characteristics of each. Briefly, an alternating current is applied across electrodes implanted at known spacings in the surface soil; the potential drop of the current between the electrodes indicates whether the subsurface geology includes any high resistance areas, indicating sand, gravel or water. Another tool, the portable seismic instrument is used to measure the velocity of energy transmitted into the earth as deep as 1,000 feet. The velocity of the energy waves travel through the subsurface geologic structure indicates the density or hardness of each layer or strata. For example, the velocity of topsoil may be 3,000 feet per sec. while limestone, granite and other potentially useful inert materials may have velocities beyond 12,000 feet per sec. Thus, where the occurrence of aggregate material is not always convenient to the shortest haul routes or major population centers, locating and utilizing them have benefitted greatly by modern technology.
CLASSES OF AGGREGATES
There are two main classes of aggregates. 1. Natural aggregates in which forces of nature have produced formations of sand and gravel deposits. These may include silts, clays or other foreign materials which are difficult to reject. Further, gradations may be quite different than those required for commercial sales. To meet such requirements, it becomes necessary to process or beneficiate natural aggregate deposits. 2. Manufactured aggregates are obtained from deposits or ledges of sedimentary rock (formed by sediments) or from masses of igneous rock (formed by volcanic action or intense heat). These are blasted, ripped or excavated and then crushed and ground to specified gradations. These deposits, too, may include undesirable materials such as shales, slates or bodies of metamorphic or igneous rock. Such deleterious materials must be removed in the processing operations. 9
PROCESSING OF AGGREGATES
Much of the equipment used in the processing of raw aggregates has been adapted from other mineral processing techniques and modified to meet the specific requirements of the crushed stone, sand and gravel industry. Other types of equipment have been introduced to improve efficiency and final product. The equipment is classified in four groups. 1. Reduction equipment, jaw, cone, roll, gyratory, impact crushers and mills; these reduce materials to required sizes or fractions. 2. Sizing equipment: Vibratory and grizzly screens to separate the fractions in varying sizes (See SCREENS, page 92-97). 3. Dewatering equipment: Sand Sorters, Log Washers, Sand and Aggregate preparation and Fine and Coarse recovery machines. 4. Sorting equipment. This can include various kinds of feeder traps and conveyor arrangements to transfer, stockpile or hold processed aggregates. As to method, there are two types of operations at most sand and gravel pits and quarry operations. They include: (a) dry process; here the material is excavated by machines or blasted loose, and is hauled to a processing plant without the use of water, and (b) wet process: This may involve pumping (dredge pumps) or excavation (draglines) of the aggregate material from a pit filled with water. The material enters the processing operation with varying quantities of water. The ideal gradation is seldom, if ever met in naturally occurring sand or gravel. Yet the quality and control of these gradations is absolutely essential to the workability and durability of the end use. The aggregate has three principal functions: 1. To provide a relatively cheap filler for cementing or asphaltic materials. 2. To provide a mass of particles that will resist the action of applied loads, abrasion, percolation of moisture, and water. 3. To keep to a minimum the volume changes resulting from the setting and hardening process and from moisture changes.
10
The influence of the aggregate on the resulting product depends on the following characteristics: 1. The mineral character of the aggregate as related to strength, elasticity, and durability. 2. The surface characteristics of the particles, particularly as related to workability and bonding within a hardened mass. Aggregate with rough surfaces or angular shapes does not place or flow as easily into the forms as smooth or rounded grains. 3. The gradation of the aggregates, particularly as related to the workability, density, and economy of the mix. Of these characteristics, the first two are self-explanatory and inherent to a particular deposit. In some cases an aggregate can be upgraded to an acceptable product by removing unsound or deleterious material, using benefication processes. Gradation, however, is a characteristic which can be changed or improved with simple processes and is the usual objective of aggregate preparation plants.
11
100
sie ve s
80 60 40 20
No s4 -1. 5i n. sie ve s
3/ 1/ 8 2 3/ 4
No s1 00 -4
11/2
Curves indicate the limits specified in ASTM for fine and coarse aggregate
FIGURE NO. 2
ACTUAL GRADATION
The ideal gradation is seldom, if ever, met in naturallyoccurring sand or gravel. In practice, the quality of the gradation of the aggregate, the workability of the concrete, cement and asphalt requirements must be balanced to achieve strength and other qualities desired, at minimum total cost. Sizing of material larger than No. 8 sieve is best and most economically done by the use of mechanical screens of various types, either dry or wet. In actual practice, however, the division between coarse aggregates which require different equipment for sizing, is set at No. 4 sieve, (Fig. 3).
Percent Weight Retained Sieve No.
3
8"
4 8 16 30 50 100 Pan
Tables have been published to facilitate these calculations, and they are based on the maximum size of the coarse aggregate which can be used for the specific type of construction planned.
13
SIEVE ANALYSIS
inches 6 5 4 3 2 1 1/2 1 1/4 1
3
% RETAINED 0 20 40 60 80
mm 100 152 127 102 76.2 50.8 38.1 31.8 25.4 19.0 12.7 9.53 6.35
/4 /2
1 3
/8 /4
SIEVE SIZE
#4 #8 #10 #16 #20 #30 #40 #50 #60 #80 #100 KEY: 35/65 Heavy Gravel 50/50 Deposit 65/35 Heavy Sand
#200 100
80
60 40 % PASSING
20
14
SIEVE ANALYSIS
inches 0 12 10 8 7 6 5 4 3 21/2 2 1 /2 KEY: Top Size 30" - 36" Coarse Top Size 24" - 27" Average Top Size 18" - 21" Fine
1
% RETAINED 20 40 60 80
mm 100 305 254 203 178 152 127 102 76.2 63.5 50.8 38.1
SIEVE SIZE
1
3
25.4 19.0
/4
/2 /8
12.7 9.53
/4
6.35
#4
#8 100
80
60 40 % PASSING
20
15
Particularly suited for wet, sticky materials, the Pioneer Apron Feeder provides positive feed action while reducing material slippage. Feeder construction includes heavy-duty and extra-heavy-duty designs depending upon the application.
16
17
NOTE: *Range is for type of feed from damp sticky to dry material.
18
Pan Travel (Ft. per Min.) 10 15 20 25 30 35 40 Yds3 55 83 110 138 165 193 220 Pan Travel (meters per (minute) 3.05 4.57 6.10 7.62 9.14 10.67 12.19 m3 42 63 84 105 126 147 168
NOTE: Considerable variance will always be encountered when calculating the capacities of feeders. Usually, experience is the best guide to what a feeder will handle under given conditions of material, rate of travel of the feeder pans, and depth of loading. The table above is based on a depth of material equal to half the feeder width, and tons are based on material weighing 2,700 pounds per cu. yd. A feeding factor of .8 has been introduced to compensate for voids, resistance to flow, etc. This factor, too, will vary with the type of material and its condition when fed. The following formula can be used to calculate the approximate capacity in cubic yards of a feeder of given width where the feeding factor is determined to be other than .8: Cu. Yds per Hr. = 2.22 (d x w x s x f); where d = depth of load on feeder, in feet: s = rate of pan travel, in feet per minute; w = width of feeder, in feet; f = feeding factor. To convert cu. yds. to tons; multiply cu. yds. by 1.35.
.914 m Wide m3 61 92 122 153 183 214 245 mt 98 147 196 245 293 343 392
1.07 m Wide m3 83 125 167 209 250 292 333 mt 133 201 267 335 401 468 533
1.22 m Wide m3 109 164 217 273 326 382 437 mt 174 262 348 437 523 610 697
1.52 m Wide m3 170 254 339 424 510 594 679 mt 272 408 544 680 816 953 1089
1.83 m Wide m3 245 367 489 611 734 856 978 mt 392 588 784 908 1176 1372 1568
Designed to convey material while separating fines, Pioneer Vibrating Feeders provide smooth, controlled feed rates to maximize capacity. Grizzly bars are tapered to self-relieve with adjustable spacing for bypass sizing. Feeder construction includes heavyduty deck plate with optional AR plate liners. Heavy-duty spring suspension withstands loading impact and assists vibration.
19
CAPACITY MULTIPLIERS FOR VARIOUS FEEDER PAN MOUNTING ANGLES FROM 0 TO 10 DOWN HILL ALL VIBRATING FEEDERS
Angle Down Hill Multiplier 0 1.0 2 1.15 4 1.35 6 1.6 8 1.9 10 2.25
NOTE: *Capacity can vary 25% for average quarry installationscapacity will usually be greater for dry or clean gravel. Capacity will be affected by the methods of loading, characteristics and gradation of material handled, and other factors.
20
H (inches)
24" BELT FEEDER (W = 18") 8 9 10 11 12 13 14 8 30" BELT FEEDER (W = 24") 9 10 11 12 13 14 8 36" BELT FEEDER (W = 30") 9 10 11 12 13 14
21
Track Mounted
Stationary
22
23
Test Sieve
4"
1" 25.4 mm
114"
112"
2"
212"
3"
312"
4" 102 mm
5" 127 mm
7" 178 mm 98 95 85 76 65 52 38 27 22 17 13 10 8 6 5 4 3 2 1
8"
19 mm
203 Sizes mm (mm) 95 90 75 65 53 40 28 23 17 13 10 8 6 5 4 3 2 1 0.5 305 254 203 178 152 127 102 76.2 63.5 50.8 38.1 31.8 25.4 19.0 12.7 9.53 6.35 #4 #8
100 100 Values Are Percent Passing 100 100 100 100 100 100 100 96 85 66 41 28 18 12 6 93 85 69 49 29 21 14 10 6 96 85 73 55 39 24 18 12 9 5 95 85 67 55 40 28 19 14 10 7 5 93 85 70 49 39 29 21 14 11 7 5 4 96 85 73 55 39 31 24 18 12 9 7 5 4 97 90 75 62 47 33 27 20 15 10 8 6 4 3 100 98 95 85 65 52 39 27 23 17 13 9 7 5 4 3 97 93 85 70 50 38 28 21 17 14 11 7 5 4 3 2 96 92 85 73 56 38 31 24 18 15 12 9 6 5 4 3 2
97 92 85 74 62 45 32 24 20 15 13 10 8 6 5 4 3 2
#4 #8
The chart on this page is particularly useful in determining the percentages of various sized particles to be obtained when two or more crushers are used in the same set up. It is also helpful in determining necessary screening facilities for making size separations. Here is an example designed to help show you how to use the percentage charts: To determine the amount of material passing 114" (31.8 mm) when the crusher is set at 2" (50.8 mm) closed side setting: find 2" (50.8 mm) at the top, and follow down the vertical line to 114" (31.8 mm). The horizontal line shows 39% passingor 61% retained.
24
4"
1" 25 mm 12 18 27 36
114" 32 mm 14 22 33 44
APPROXIMATE CAPACITIES AT PEAK TO PEAK CLOSED SIDE SETTINGS (IN TPH)* 112" 2" 212" 3" 312" 4" 5" 6" 7" 8" 9" 38 mm 19 29 44 59 36 54 81 51 mm 24 36 55 73 45 68 102 61 64 mm 28 44 67 89 54 81 122 74 109 145 165 76 mm 89 mm 102 mm 127 mm 152 mm 178 mm 203 mm 228 mm
10" 254 mm
11" 279 mm
12" 304 mm
19 Elect Diesel mm 1016 1024 1036 1047 1524 1536 1654 1830 2036 **2436 2148 2649 2854 **3042 3163 **3350 **3546 **4248 15 25 40 40 75 125 60 100 100 125 150 200 150 200 200 200 250 25 40 60 110 60 110 175 90 140 150 170 190 250 190 250 250 250 310 10 15 22 29
72 109 163 98 139 153 186 211 241 200 330 275 275
136 204 123 156 171 207 235 268 223 370 302 302 324
187 205 248 282 323 268 450 350 350 376
625
688
752
875
NOTE: *Based on material weighing 2,700 lbs. per cubic yard. Capacity may vary as much as 25%. **Larger settings may be obtained with other than standard toggle plateconsult Factory.
25
26
4"
1" 25 mm
114" 32 mm
APPROXIMATE CAPACITIES AT PEAK TO PEAK CLOSED SIDE SETTINGS (IN TPH)* 112" 2" 212" 3" 312" 4" 5" 6" 7" 8" 9" 38 mm 51 mm 64 mm 165 76 mm 188 265 212 265 89 mm 211 300 240 305 275 102 mm 235 334 267 372 360 423 127 mm 282 402 320 459 416 492 471 373 530 484 574 528 426 611 553 654 735 816 692 152 mm 178 mm 203 mm 228 mm
10" 254 mm
11" 279 mm
12" 304 mm
3352
** 4450
NOTE: *Based on material weighing 2,700 lbs. per cubic yard. Capacity may vary with the material characteristics. **Larger settings may be obtained with other than standard toggle plateconsult Factory.
27
Making a cubical product necessary for asphalt and concrete specifications poses many equipment problems for the aggregate producer. Among these problems are abrasive wear, accessibility for hammer maintenance or breaker bar changes and bridging in the crushing chamber. Pioneer Impact Crusher units are designed to help over-come problems faced by producers and at the same time to provide maximum productivity for existing conditions.
28
PIONEER PRIMARY IMPACT CRUSHERS (NEW HOLLAND STYLE)APPROXIMATE PRODUCT GRADATIONOPEN CIRCUIT
Test Sieve Sizes (in.) 6" 5" 4" 3" 212" 2" 112" 114" 1" 100 96 90 77 64 57 50 41 32 26 20 17 12 8 5 3 2 100 97 89 75 67 58 47 37 30 23 19 14 9 6 4 3 3850 Normal Setting 4654 6064 Test Sieve Sizes (mm) 152 100 98 89 80 67 56 50 44 37 28 23 17 15 10 6 4 3 2 137 102 76.2 63.5 50.8 38.1 31.8 25.4 19.1 12.7 9.53 6.35 #4 #8 #16 #30 #50 #100
Recommended HP Size 3850 4654 6064 Electric 250-300 300-400 400-600 Diesel 350-450 450-600
Approx. Capacities* TPH 250-450 400-750 mt/h 227-409 364-682 Maximum Feed Size 24" 30" 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 type of feed, adjustment of lower breaker bar, etc.
29
These Impact Crushers are designed for recycling concrete, asphalt as well as traditional aggregate crushing applications. The Maximum Performance Rotor (MPR) offers the mass of a solid design with the clearances of an open configuration.
30
Maximum Feed Size** Size 5260 4250 4233 Recycle 36"x36"x12" 30"x30"x12" 24"x24"x12" Limestone 10"-12" 10"-12" 8"-10" Hard Rock 8"-10" 8"-10" 6"-8"
8000 fpm
% Cumulative Passing
70% 60% 50% 40% 30% 20% 10% 0% 50 mesh 8 mesh 1" 3" 10"12"
FEED
NOTE: *Capacity depends on feed size and gradation, type of material, etc. ** Limestone and hard rock feed sizes are based on secondary applications.
31
1400 LS Cone
33
11. Crusher cone head is properly blocked prior to transport. 12. Only authorized OEM parts or factory approved wear parts are used. Application 1. Reduction ratio limited to 6 to 1 below 1" closed side setting and 8 to 1 above 1" closed side setting provided no bowl float occurs. 2. Manganese chamber configuration conforms to the factory recommended application guidelines. 3. Crusher is operated at the factory recommended rpm for the application. 4. Crusher feed is consistent providing an even flow of material, centered in the feed opening, and covering the mantle nut at all times. 5. Crusher input horsepower does not exceed factory specifications. 6. Crusher discharge chamber is kept clear of material buildup. 7. If the crusher can not be totally isolated from metal in the feed material, a magnet should be used over the crusher feed belt. 8. Crusher feed does not fall from a height more than 36" into the crushing chamber. 9. Crusher is always shut down prior to adjusting the closed side setting digital readout. Crusher is never operated at zero closed side setting.
35
36
Closed Side Setting (CSS) Gross Throughput Closed Side Setting (CSS) Recirculating Load Gross Throughput Net Throughput
2"
8"
4"
8"
1" 25.4 mm
270-330
114" 32 mm
310-385
112" 38.1 mm
330-415
134" 44.5 mm
350-440
2" 50.8 mm
370-460
12.7 mm 170-210
15.87 mm
190-240
19.05 mm
215-270
22.22 mm
240-300
8"
2"
8"
4"
8"
1" 25.4 mm
21% 270-330 213-261
114" 32 mm
28% 310-385 223-277
12.7 mm
15% 170-210 145-178
15.87 mm
15% 190-240 162-204
19.05 mm
17% 215-270 178-224
22.22 mm
20% 240-300 192-240
Minimum closed side setting is the closet setting possible that does not induce bowl float. Actual minimum closed side setting and production numbers will vary from pit to pit and are influenced by such factors as nature of feed material, ability to screen out fines, manganese condition, and low relief system pressure.
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm 100
100 100 98 100 97 100 100 100 100 100 100 100 98 95 85 75 63 51 42 35 31 24 18 15 12 9 7 97 94 89 75 65 52 42 36 30 26 21 15 13 11 8 6 99 95 90 85 69 61 50 36 30 26 22 17 11 10 8 7 6 99 95 91 85 75 63 56 45 33 28 24 20 15 9 8 7 6 5 99 95 88 83 73 63 51 43 37 28 23 20 17 13 8 7 6 5 4 99 95 87 80 71 58 50 42 35 29 21 18 16 14 10 6 5 4 4 3 99 97 90 79 70 61 49 42 33 27 23 18 15 12 10 8 5 4 3 3 2 94 89 82 72 60 49 41 34 28 21 19 16 14 12 9 8 6 4 3 2 1.5 1 95 91 86 79 68 56 45 38 32 28 23 17 15 13 11 10 7 6 4 3 2 1.5 1 0.5 95 92 88 83 76 66 56 46 36 30 26 22 19 14 13 11 9 8 5 4 3 2 1.5 1 0.5 0.5
16"
1
4"
4M
5
32"
Bowl Liner: 456073 Mantle: 456071 All Dimensions in inches A B C Max. Feed Material 1112 2 11 1012 1014 1114 112 1034 10 10 11 114 3 3 9 4 10 4 1 8 Product Range: 1" to 212" Minus Pinion Speed: 850 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
Bowl Liner: 456074 Mantle: 456071 All Dimensions in inches A B C Max. Feed Material 8716 114 712 7716 8316 1 6 7316 7 718 818 8 514 3 7 8 4 412 Product Range: 34" to 114" Minus Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
Bowl Liner: 456264 Mantle: 456071 All Dimensions in inches A B C Max. Feed Material 7 51116 518 412 8 3 9 3 4 8 5 16 4 5 9 4316 538 16 478 1 5516 434 418 2 Product Range: 12" to 78" Minus Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.) 39
Bowl Liner: 456243 Mantle: 456242 All Dimensions in inches A B C Max. Feed Material 3 518 4 4 3516 5 5 334 314 8 1 3316 478 2 3 3 318 434 8 214 Product Range: 34" to 58" Minus Pinion Speed: 950 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
40
LINERS
PINION SPEED
SHEAVE
N N M
M M M
41
42
Closed Side Setting (CSS) Gross Throughput Closed Side Setting (CSS) Recirculating Load Gross Throughput Net Throughput
2"
8"
4"
8"
1" 25.4 mm
340-425
114" 32 mm
405-505
112" 38.1 mm
440-550
134" 44.5 mm
475-595
2" 50.8 mm
500-625
12.7 mm 210-260
15.87 mm
250-315
19.05 mm
290-365
22.22 mm
315-395
8"
2"
8"
4"
8"
1" 25.4 mm
21% 340-425 269-336
114" 32 mm
28% 405-505 292-364
12.7 mm
15% 210-260 178-221
15.87 mm
15% 250-315 212-268
19.05 mm
17% 290-365 241-303
22.22 mm
20% 315-395 252-316
Minimum closed side setting is the closet setting possible that does not induce bowl float. Actual minimum closed side setting and production numbers will vary from pit to pit and are influenced by such factors as nature of feed material, ability to screen out fines, manganese condition, and low relief system pressure.
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm 100
100 100 98 100 97 100 100 100 100 100 100 100 98 95 85 75 63 51 42 35 31 24 18 15 12 9 7 97 94 89 75 65 52 42 36 30 26 21 15 13 11 8 6 99 95 90 85 69 61 50 36 30 26 22 17 11 10 8 7 6 99 95 91 85 75 63 56 45 33 28 24 20 15 9 8 7 6 5 99 95 88 83 73 63 51 43 37 28 23 20 17 13 8 7 6 5 4 99 95 87 80 71 58 50 42 35 29 21 18 16 14 10 6 5 4 4 3 99 97 90 79 70 61 49 42 33 27 23 18 15 12 10 8 5 4 3 3 2 94 89 82 72 60 49 41 34 28 21 19 16 14 12 9 8 6 4 3 2 1.5 1 95 91 86 79 68 56 45 38 32 28 23 17 15 13 11 10 7 6 4 3 2 1.5 1 0.5 95 92 88 83 76 66 56 46 36 30 26 22 19 14 13 11 9 8 5 4 3 2 1.5 1 0.5 0.5
16"
1
4"
4M
5
32"
43
Bowl Liner: 546035 Mantle: 546034 All Dimensions in inches A B C Max. Feed Material 13 2 1214 1112 1 3 1 12 4 1 2 12 11 4 11 1212 114 10 1034 1214 1 8 Product Range: 1" to 212" Minus Pinion Speed: 850 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
Bowl Liner: 546036 Mantle: 546034 All Dimensions in inches A B C Max. Feed Material 9316 114 812 71116 9 1 7 712 7 738 878 8 514 3 714 834 4 412 Product Range: 34" to 114" Minus Pinion Speed: 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
Bowl Liner: 546037 Mantle: 546034 All Dimensions in inches A B C Max. Feed Material 5 638 1 534 7 478 614 8 514 3 3 1 6 8 412 4 4 4 5 5 4 8 6 8 334 Product Range: 12" to 78" Minus Pinion Speed: 900 to 950 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.) 45
Bowl Liner: 546039 Mantle: 546038 All Dimensions in inches A B C Max. Feed Material 3 414 4 312 234 5 418 338 258 8 1 212 4 2 314 3 7 3 2 8 3 8 8 318 Product Range: 14" to 58" Minus Pinion Speed: 950 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
Bowl Liner: 546068 Mantle: 546038 All Dimensions in inches A B C Max. Feed Material 5 218 258 8 278 1 2 312 2 234 3 7 3 3 8 258 1 8 8 3 1 1 1 4 3 4 4 212 Product Range: 14" to 12" Minus Pinion Speed: 950 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.) 46
LINERS
PINION SPEED
BORE
SHEAVE
BORE WEG
N N N
412 4 2 412
1
J J M
378 3 8 378
7
47
48
Closed Side Setting (CSS) Gross Throughput Closed Side Setting (CSS) Recirculating Load Gross Throughput Net Throughput
2"
8"
4"
8"
1"
25.4
114"
32
112"
38.1
134"
44.5
2"
50.8
12.7
15.87
19.05
22.22
mm
1200LS 1400LS 125-165 170-215
mm
140-195 200-255
mm
165-220 225-285
mm
180-245 230-305
mm
200-270 240-350
mm
220-320 265-390
mm
240-345 295-405
mm
260-365 315-450
mm
270-385 330-480
4"
16"
8"
2"
8"
4"
8"
1"
25.4
6.35
7.94
9.52
12.7
15.87
19.05
22.22
mm
15% 1200LS 1400LS 1200 LS 1400LS 75-90 64-77
mm
15% 90-105 115-145 77-90 98-123
mm
16% 115-145 145-190 97-122 122-160
mm
20% 145-190 190-235 116-152 152-188
mm
20% 165-220 225-280 132-176 180-224
mm
20% 185-250 240-315 148-200 192-252
mm
26% 205-275 245-335 152-204 181-248
mm
28% 225-300 265-375 162-216 191-270
Minimum closed side setting is the closet setting possible that does not induce bowl float. Actual minimum closed side setting and production numbers will vary from pit to pit and are influenced by such factors as nature of feed material, ability to screen out fines, manganese condition, and low relief system pressure.
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm 100
100 100 98 100 97 100 100 100 100 100 100 100 98 95 84 74 61 48 41 35 31 24 18 15 12 9 7 97 94 88 73 63 50 42 36 30 26 21 15 14 12 9 6 99 94 87 80 63 54 44 35 30 26 22 17 11 10 8 7 6 99 93 87 80 69 52 46 36 32 28 24 20 15 9 8 7 6 5 97 90 86 80 69 58 44 37 32 26 23 20 18 13 8 7 6 5 4 96 90 82 74 65 55 47 37 31 26 21 18 16 14 10 6 5 4 4 3 97 91 83 72 64 54 46 39 28 25 21 18 15 12 10 8 5 4 3 3 2 94 88 80 70 58 48 40 34 28 21 19 16 14 12 9 8 6 4 3 2 1.5 1 95 91 86 79 68 56 45 38 32 28 23 17 15 13 11 10 7 6 4 3 2 1.5 1 0.5 95 92 88 83 76 66 56 46 36 30 26 22 19 14 13 11 9 8 5 4 3 2 1.5 1 0.5 0.5
16"
1
4"
4M
5
32"
Bowl Liner: 450127 All Dimensions in inches Mantle: 450128 A B C Max. Feed Material 9 934 2 938 1 1 1 9 2 1 2 9 8 2 814 914 114 834 8 9 1 5 Product Range: 34" to 112" Minus Pinion Speed: 750 to 850 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.) 50
Bowl Liner: 450177 All Dimensions in inches Mantle: 450128 A B C Max. Feed Material 1 458 4 514 7 1 7 3 8 5 8 8 412 3 3 3 4 5 4 438 1 312 434 2 4 Product Range: 12" to 12" Minus Pinion Speed: 800 to 900 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
51
52
LINERS
PINION SPEED
SHEAVE
M M M M
J J J J
LINERS
PINION SPEED
SHEAVE
N N N N
J J J J
Bowl Liner: 540113 All Dimensions in inches Mantle: 540101 A B C Max. Feed Material 12 2 1158 1114 1114 112 11 1034 1012 11 114 8 1014 1034 1 6 Product Range: 1" to 212" Minus Pinion Speed: 700 to 800 RPM Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
Bowl Liner: 540115 All Dimensions in inches Mantle: 540101 A B C Max. Feed Material 912 114 918 834 1 1 8 2 9 4 1 878 3 1 7 8 8 9 8 8 8 3 9 4 814 4 Product Range: 58" to 1" Minus Pinion Speed: 700 to 850 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.) 53
Bowl Liner: 540114 All Dimensions in inches Mantle: 540101 A B C Max. Feed Material 1 434 4 512 7 334 514 8 412 5 1 3 3 8 5 8 4 438 1 5 3 2 5 8 414 Product Range: 38" to 34" Minus Pinion Speed: 750 to 850 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
Bowl Liner: 540274 All Dimensions in inches Mantle: 540273 A B C Max. Feed Material 3 212 418 4 314 3 5 2 8 4 8 318 1 1 7 3 8 3 2 4 2 3 118 334 8 3 Product Range: 38" to 58" Minus Pinion Speed: 800 to 900 RPM Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs then you have gone beyond the allowable reduction ratio.)
54
LINERS
PINION SPEED
SHEAVE
750 RPM 800 RPM 850 RPM 900 RPM 950 RPM
N N N N N
M M M M M
LINERS
PINION SPEED
SHEAVE
P P P N
M M M M
55
FEED OPENING & APPROXIMATE CAPACITY VS. SETTING MAGNA-CONE M6000 CONE CRUSHEROPEN CYCLE
See Notes (Page 31)
Closed Side Setting in.
3 7
Coarse Bowl Coarse Bowl Medium Bowl Medium Bowl Feed Opening Feed Opening Feed Opening Feed Opening @ Closed Stroke @ Open Stroke @ Closed Stroke @ Open Stroke in. mm in. mm in. 7716 7916 912 934 10116 10516 10916 101316 241 1012 267 271 278 284 290 297 758 71516 8316 mm 189 192 194 202 208 in. 8516 8716 8916 81316 9 mm
mm 19 22 25 32 38 44 51 57
4" 8"
211 195-245 177-222 214 210-270 190-245 217 225-285 204-259 224 250-315 227-286 229 280-350 254-318 310-390 281-354 335-425 304-386 365-460 331-417
275 111116
APPROXIMATE PRODUCT GRADATION MAGNA-CONE M5000 AND M6000 CONE CRUSHER IN OPEN CYCLECLOSED SIDE SETTING
See Notes (Page 31)
Test Sieve Sizes in. 5" 4" 3" 212" 2" 112" 114" 1"
3 1 3 1
8" 16 mm
1" 2" 4" 4" 2" 4" 4" 19 mm 25 mm 32 mm 38 mm 44 mm 51 mm 57 mm 100 Values Shown Are Percent Passing 100 100 100 100 94 90 75 54 35 28 22 18 13 10 8 5 2 94 83 75 55 40 27 22 18 15 10 8 5 3.5 1.5 95 87 75 60 46 35 24 20 15 13 8 7 4.5 3 1 100 97 90 82 66 52 43 32 22 18 14 11 7 5 3.5 2.5 0.9 100 93 85 75 60 49 40 30 20 17 13 10 5 4 3 1.5 0.5 94 82 75 65 47 41 32 25 17 13 9 7 4 3 2 1 0.5
11
11
13
21
100 95 83 55 39 30 25 19 15 11 8 4
97 90 75 45 34 27 22 16 12 9 6 2
56
FEED OPENING & APPROXIMATE CAPACITY VS. SETTING MAGNA-CONE M5000 CONE CRUSHEROPEN CYCLE
See Notes (Page 31)
Closed Side Setting in.
5
Coarse Bowl Coarse Bowl Medium Bowl Medium Bowl Feed Opening Feed Opening Feed Opening Feed Opening @ Closed Stroke @ Open Stroke @ Closed Stroke @ Open Stroke in. mm in. mm in. 718 714 858 834 9 914 912 934 219 222 229 235 241 248 938 912 934 10 1014 1012 238 241 248 254 260 267 738 712 734 mm 181 184 187 190 197 in. 778 8 818 814 812 mm
mm 16 19 22 25 32 38 44 51
8"
200 135-175 123-159 203 145-185 132-168 206 155-195 141-177 210 170-215 154-195 216 195-245 177-222 210-270 190-245 235-300 213-272 260-330 236-300
3 7
4" 8"
APPROXIMATE PRODUCT GRADATION MAGNA-CONE M5000F AND M6000F FINE HEAD CONE CRUSHER IN OPEN CYCLECLOSED SIDE SETTING
See Notes (Page 31)
Test Sieve Sizes in. 2" 112" 114" 1"
3 5 1 3 1
3 " 8 10 mm
1 " 2 13 mm
5 " 8 16 mm
3 " 4 19 mm
1" 25 mm 100 94 90 75 54 46 35 30 24 19 14 11 8 5 2
100 97 90 75 60 45 36 28 23 17 13 10 6 2
57
58
FEED OPENING & APPROXIMATE CAPACITY VS. SETTINGM6000F CONE CRUSHERSee Notes (Page 31)
Closed Side Setting Coarse Bowl Feed Opening @ Closed Stroke Coarse Bowl Feed Opening @ Open Stroke Fine Bowl Feed Opening @ Closed Stroke Fine Bowl Feed Opening @ Open Stroke Capacity (Total) See Note 3 (Page 31) Open Capacity (Net) See Note 4 (Page 31) Closed
mm 10 13 16 19 22 25
in.
mm
in.
mm
94 98 103 108
mm 54 57 60 64
mm 89 92 95 98
FEED OPENING & APPROXIMATE CAPACITY VS. SETTINGM5000F CONE CRUSHERSee Notes (Page 31)
Closed Side Setting Coarse Bowl Feed Opening @ Closed Stroke Coarse Bowl Feed Opening @ Open Stroke Fine Bowl Feed Opening @ Closed Stroke Fine Bowl Feed Opening @ Open Stroke Capacity (Total) See Note 3 (Page 31) Open Capacity (Net) See Note 4 (Page 31) Closed
mm 10 13 16 19 22 25
mm 92 95 98 102 105
mm 48 51 54 57
mm 79 82 86 89
59
PIONEER ROLL CRUSHERS APPROXIMATE TWIN AND TRIPLE ROLL CRUSHER GRADATIONOPEN CIRCUIT
Roll Crusher Settings Test Test Sieve Sieve 1 " 3 " 1 " 3 " 1 1 1 1" 1 4" 1 2" 2" 2 2" 3" 4" Sizes Sizes 4 8 2 4 (in.) 6.35 9.53 12.7 19.0 25.4 31.8 38.1 50.8 63.5 76.2 102 (mm)
mm 8" 6" 5" 4" 3" 212" 2" 112" 114" 1"
3 1 3 1
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm 203 152 127 85 102 75.2 63.5 50.8 38.1 31.8 25.4 19.0 12.7 9.53 6.35 #4 #8 #16 #30 #50 #100
63 50 36 26 22 17 14 10 8 5 4 3 2 1 0.5 0
Gradation result may be varied to greater fines content by increasing feed and corresponding horsepower.
60
PIONEER ROLL CRUSHERS APPROXIMATE TWIN AND TRIPLE ROLL CRUSHER GRADATIONCLOSED CIRCUIT WITH SCREEN
Roll Crusher Settings Test Test Sieve Sieve 1 3 " 1 " 3 " 1 1 1 1" 1 4" 1 2" 2" 2 2" 3" 4" Sizes Sizes 4" 8 2 4 (in.) 6.35 9.53 12.7 19.0 25.4 31.8 38.1 50.8 63.5 76.2 102 (mm)
mm 4" 3" 212" 2" 112" 114" 1"
3 1 3 1
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm 100 102 76.2 63.5 50.8 38.1 31.8 25.4 19.0 12.7 9.53 6.35 #4 #8 #16 #30 #50 #100
Values Shown are Per Cent Passing Roll Setting 80% of Screen Mesh Size
100 100 100 100 100 100 75 55 25 14 8 5 3 80 53 35 19 11 6 4 3 75 55 33 22 14 8 5 3 2 80 55 36 23 17 12 7 4 3 2 85 66 41 28 19 15 10 6 4 3 2 90 75 55 33 24 18 14 9 5 3 2 1 100 79 63 46 33 22 18 13 10 7 4 3 2 1 100 85 63 50 39 28 20 16 11 9 6 3 2 1 0.5 100 91 75 55 44 34 25 18 14 10 8 5 3 2 1 0.5
79 64 48 35 29 23 18 13 10 7 5 3 2 1 0.5 0
Gradation result may be varied to greater fines content by increasing feed and corresponding horsepower.
61
APPROXIMATE CAPACITIES IN TPH FOR OPEN CIRCUIT (Use 85 percent of these values in closed circuit)
Roll Settings Size
1
4"
2"
4"
1"
114"
112"
2"
212"
3"
2416 16 31 47 63 79 94 3018 25 50 75 100 125 150 200 3024 33 66 100 133 166 200 266 3030 41 82 125 166 207 276 344 414 4022 34 69 103 138 172 207 276 344 414 4030 53 106 160 213 266 320 426 532 640 4240 70 141 213 284 354 426 568 709 853 5424 44 87 131 175 228 262 350 437 525 5536 65 130 195 261 326 390 522 652 782 *Based on 50% of theoretical ribbon of material of 100# / Ft.3 Bulk DensityCapacity may vary as much as 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed sizeTo find Yd.3 /Hr. multiply by .74. For larger settingsconsult Factory.
4 8 1 2 3 4
3
2 4
2 4
1 114 1 1 2 2 212 3
1 112 2 238 3 2 4
APPROXIMATE CAPACITIES IN MT/H* FOR OPEN CIRCUIT (Use 85 percent of these values in closed circuit)
Roll Settings 6.35 12.7 19.0 25.4 31.7 38.1 50.8 63.5 76.2 Size mm mm mm mm mm mm mm mm mm 2416 14 28 43 57 72 85 3018 23 45 68 91 113 136 181 3024 30 60 91 121 150 181 241 3030 37 74 113 150 188 227 301 4022 31 62 93 125 156 188 250 312 375 4030 48 96 145 193 241 290 386 483 580 4240 64 128 193 257 321 386 514 644 773 5424 40 79 119 159 207 238 317 396 476 5536 59 118 177 237 296 354 473 591 709 *Based on 50% of theoretical ribbon of material of 1600 kg/m3 Bulk DensityCapacity may vary as much as 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed sizeTo find cubic meters per hour, multiply by 1.6. For larger settingsconsult Factory.
4"
2"
4"
1"
114"
112"
2"
212"
3018 37 75 112 150 187 225 3024 52 104 156 208 260 312 3030 65 130 195 260 325 390 4022 58 117 176 234 292 350 468 584 4030 79 159 238 318 398 476 636 796 4240 105 212 317 424 530 634 848 1061 5424 65 131 198 262 328 392 524 655 5536 97 195 293 391 489 586 782 977 *Based on 75% of theoretical ribbon of material of 100# / Ft.3 Bulk DensityCapacity may vary as much as 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed sizeTo find Yd.3 / Hr. multiply by .74. For larger settingsconsult Factory.
4 8 2 3 4
1 114 112 2 212
30" Dia. Rolls Larger Max. Setting Feed 1 2 1 3 4 112 1 2 112 3 7 1 8 312 2 312 2 312
40" or 42" Dia. Rolls Larger Max. Setting Feed 9 15 114 13 116 178 1 8 178 11116 334 214 5 212 5 3 2 4 5 3 5 3 5
54" or 55" Dia. Rolls Larger Max Setting Feed 5 8 112 15 16 214 15 16 214 11316 412 2716 6 2716 6 3 6 3 6 3 6
3018 33 68 102 136 170 204 3024 47 94 141 189 236 283 3030 59 118 177 236 295 354 4022 53 106 160 212 265 317 424 530 4030 72 144 216 288 361 432 577 722 4240 96 192 288 384 481 576 769 962 5424 59 119 180 238 297 356 475 594 5536 88 177 266 355 444 532 709 886 *Based on 75% of theoretical ribbon of material of 1600 kg/m3 Bulk DensityCapacity may vary as much as 25%. The capacity at a given setting is dependent on HP, slippage, type of shells and feed sizeTo find cu. meters per hour, multiply by 1.6. For larger settingsconsult Factory.
CAPACITY MULTIPLIERS FOR OPEN CIRCUIT TWIN FEED VS. SINGLE FEED TRIPLE ROLLS
Triple roll twin feed capacities are obtained by selecting a multiplier from the chart (depending on coarse/fine feed ratio) and applying the same to the single feed triple roll capacity. Roll crusher capacities at given settings will vary depending on horsepower available, slippage of feed on shells in crushing chamber, type of shells, and size of feed. Based on a reduction ratio of 2 to 1 in each stage. Feed Split Ratio Coarse/Fine 20/80 30/70 40/60 50/50 60/40 67/33 70/30 80/20 90/10 Capacity Through Crusher .83 .97 1.13 1.35 1.66 2.00 1.95 1.75 1.55 Capacity That is Product Size .73 .77 .85 .95 1.12 1.30 1.24 1.04 .82
(12.7 mm) 1
2" 1"
(25.4 mm)
(1) Single feed capacity for 12"(12.7 mm) Product = 159 TPH (144 t/h). (2) Twin feed capacity with feed split ratio coarse/fine 67/33 is 159 x 2 = 318 TPH (144 x 2 = 288 mt/h). (3) Single feed open circuit product 159 x .85 = 135 TPH (144 x .85 = 122 mt/h). (4) Twin feed open circuit product is 159 x .85 x 1.3 = 175 TPH (144 x .85 x 1.3 = 159 mt/h). 66
4030
19
91
310
680
4240 5424
17 19
88 118
320 310
680 700
5536
17
88
250
700
8 8 8 8 12
18 19 19
82 73 91
30-32 2814-33 ( 7 x 18) 30-32 ( 7 x 18) 39-42 3712-4212 (10 x 22) 40-43 (11 x 22) 39-42 3712-4212 (10 x 22) 40-43 (11 x 22) 41-45 53-58 53-57 (12 x 36)
4030
19
91
310
680
4240 5424
17 19
88 118
320 310
680 700
5536
17
88
250
700
67
These Vertical Shaft Impact Crushers are best applied in tertiary and quaternary applications and various secondary applications. Rock fed to the crushers accelerator mechanism (table or rotor) is flung outwards by centrifugal force against the stationary anvils or hybrid rock shelf for free-body impacting. The proper chamber configuration is application dependent. Major crushing advantages include: precise gradation control; production of chips and asphalt aggregates fines; compliance with cubical and fracture count specifications, for todays tight specification requirements such as Superpave.
68
Feed Tube Diameter Inch 812 812 1138 1138 14.0 16.0 16.0 16.0 18.0
Capacity Effective Crushing Range (2) TPH 75-125 75-150 150-250 150-300 250-400 300-450 300-450 300-500 300-500 MTPH 67-112 67-135 135-223 135-267 227-356 267-401 267-401 367-454 267-445
Standard Impeller Table Speed Range RPM 720-2000 720-2000 700-1400 700-1400 800-1200 800-1200 800-1200 800-1200 800-1080
Recommended Electric Horsepower H.P. 75-150 150 250 300 400-500 400-500 400-500 400-500 400-600
Table/Anvil Clearance Inch 10.4 8.8 8.7 10.25 11.75 14.75 MM 260 220 218 (256) 294 369
Explosion Chamber Volume Cubic Inch 4,635 4,635 10,120 10,120 10,940 17,360 17,360 17,360 26,020
EV-Models WK2 Lbs-Ft 1,100 1,100 2,400 2,400 3,200 3,830 3,830 3,500 5,600
Approximate Weight (Electric Shown) Lbs 13,200 13,700 18,000 19,000 24,000 29,600 29,600 29,100 32,100 Kgs 6,000 6,000 8,182 8,182 11,000 13,320 13,320 13,320 14,595
8"
#4
3
8"
NOTE: (H) in the model number denotes hardparts configuration also referred to as standard configuration. (A) in the model number denotes autogenous configuration. The specification and production rates shown apply to semi and fully autogenous. (1) Max feed size restriction can vary with regards to material density, crushability, elongation, and impeller table speed or configuration. (2) Feed size and throughput tonnage based on material weighing 100 lbs. per cubic foot.
69
70
Secondary
Sieve Size inches 6" 5" 4" 3" 2" 112" 114" 1" 7 " 8 3 " 4 5 " 8 1 " 2 3 " 8 1 " 4 #4M #8M #16M #30M #50M #100M #200M Sieve Size mm 152mm 125mm 100mm 75mm 50mm 37.5mm 31.5mm 25.0mm 22.4mm 19.0mm 16.0mm 12.5mm 9.5mm 6.3mm 4.75mm 2.36mm 1.18mm 600um 300um 150uM 75uM Feed Scalped at 112" (1)
AVERAGE MATERIALS CRUSHER OUTPUT, (2) USING 3-SHOE/4-SHOE IMPELLER Max. Speed 80% of Max. Speed Output % Passing 100% 99 97 86 70 63 52 48 40 36 30 24 19 16 11 8 6 4 3 2 50% of Max. Speed Output
100% 96 90 86 78 74 68 62 53 44 35 29 17 14 10 7 5 3
100% 99 91 81 77 68 64 56 51 42 34 27 24 15 13 9 6 4 2
PIONEER SECONDARY CRUSHING AVERAGE MATERIALS (BASALT, HARD LIMESTONE, GRAVEL/DOLOMITE) W/STANDARD CONFIGURATION
NOTE: (1) Feeds shown are typical feed gradations when following a primary jaw set at 3" to 4" or a primary impactor set at 2" to 3" with product sized material removed. (2) Crusher outputs show average values based on field experience, and are taken before screening product sized material out. The figures are provided for estimating required screen areas and tertiary crushing equipment when used with the expected tonnage of crusher throughput. Values will differ with each specific crushing application, so these figures are not guarantees. Factors that can affect output gradation 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
Sieve Size inches 3" 2" 112" 1" 3 " 4 1 " 2 3 " 8 1 " 4 #4M #8M #16M #30M #50M #100M #200M
Models 1500H, 2500H, 82H 3" Feed 2" Feed Feed Typical Output 100% 98 94 83 69 52 40 28 20 14 9 6 4 3 2 Feed Typical Output 100% 98 90 78 60 46 33 24 15 10 7 5 4 3
Sieve Size mm 75mm 50mm 37.5mm 25mm 19mm 12.5mm 9.5mm 6.3mm 4.75mm 2mm 1.18mm 600uM 300uM 150uM 75uM
100% 95 80 62 40 30 15 10 7 5 4 3
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.
71
72
Tertiary
Sieve Size inches 3" 2" 112" 1" 3 " 4 1 " 2 3 " 8 1 " 4 #4M #8M #16M #30M #50M #100M #200M
Models 1500H, 2500H, 82H 3" Feed Feed Typical Output 100% 98 95 87 79 68 57 46 37 26 17 11 7 5 4
Sieve Size mm 75mm 50mm 37.5mm 25mm 19mm 12.5mm 9.5mm 6.3mm 4.75mm 2mm 1.18mm 600uM 300uM 150uM 75uM
Feed
100% 94 85 73 62 49 40 27 18 12 8 6 4
100% 99 90 78 63 52 33 21 15 10 6 4
Quaternary
Models 1500H, 2500H, 82H Approx. Crusher Output Low Range High Range % Passing 100% 99 90 78 63 52 33 21 15 10 6 4 High Range Screened Average at #4M*
Feed Sieve Size inches 1" 3 " 4 1 " 2 3 " 8 1 " 4 #4 #8 #16 #30 #50 #100 #200 Sieve Size mm 25mm 19mm 12.5mm 9.5mm 6.3mm 4.75mm 2.36mm 1.18mm 600uM 300uM 150uM 75uM
100% 95 80 62 40 30 15 10 6 5 4 3
100% 97 85 70 52 41 24 15 11 7 5 3
100% 75 48 34 22 13 9
* Shows high range with the effect of normal field screening inefficiencies. 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 specifications regarding a #4M minus gradation.
73
74
Autogenous
Sieve Size inches 2" 112" 114" 1" 3 " 4 1 " 2 3 " 8 1 " 4 #4M #8M #16M #30M #50M #100M #200M
Sieve Size mm 50mm 37.5mm 31mm 25mm 19mm 12.5mm 9.5mm 6.3mm 4.75mm 2mm 1.18mm 600uM 300uM 150uM 75uM
100% 96 90 76 58 45 37 25 17 13 8 5 3
Based upon material weighing 2,700 lbs.. per cubic yard (1600 kg/m3). Capacities may vary as much as 25% dependent upon methods of loading, characteristics and gradation of material, condition of equipment and other factors.
STANDARD CONFIGURATION SHOE & ANVIL Impeller shoes in chamber fling rock at true right angles to stationary anvils; rock gradations controlled by impeller table speed. Variable reduction ratios of 10:1 to 3:1.
75
100 Values are percent passing 100 100 97 100 100 97 97 95 100 98 100 98 94 94 90 100 97 95 97 95 90 90 84 98 93 90 93 90 82 82 74 90 82 79 82 79 67 67 57 100 81 71 66 71 66 53 53 45 100 95 64 54 50 54 50 38 38 32 95 89 50 41 38 41 38 27 27 22 82 65 29 22 21 22 21 15 15 12 48 35 14 11 10 11 10 7 7 6 25 20 8 6 5 6 5 4 4 3 20 15 6 4 3 4 3 3 3 2 14 10 4 3 2 3 2 2 2 1 9 7 2 2 1 2 1 1 1 0
HORSEPOWER RECOMMENDED
Size 4034 5042 4034F Electric 250* 300 500 Diesel (Cont.) 300 400 600
*For 34" to 1" (19.1 mm to 25.4 mm) product at capacities indicated. More power is required for finer products and/or greater capacities than indicated.
APPROXIMATE CAPACITIES**
Basic Product Size
Unit Size 4034 5042 4034F TPH mt/h TPH mt/h TPH mt/h Ag. Lime 30-50 27-45 40-70 36-64 30-50 27-45
1 " 3 " 1" 114" 112" 4" 2 4 6.35 mm 12.5 mm 19.1 mm 25.4 mm 31.8 mm 38.1 mm 1
80-120 100-140 120-160 140-180 73-109 91-127 109-145 127-163 120-170 150-200 180-230 210-260 109-154 136-181 163-209 191-236
**Based on material weighing 2,700 lbs. per cubic yard (1600 kg/m3will vary depending on feed size, arrangement, etc. 76
Speed RPM** 3" 970 970 970 970 700 700 700 700 700 700
Ag. Lime 1 " 4 1 " 2 3 " 4 3 " 4 7 " 8 1" 114" 112" 134"
1
16" 3 " 8
1 2 3 4 5 6 7 8 9 10 11 11 11 11
4" 8 6
8" 8 6 4
2"
4"
1"
112"
2"
4 3
4 4 4 3
2 4 8 8 6 4
1 7 7 3 3 4 8
1 2 2 2 5 4 4 8
1 1 1
4 5 6 11 713 11 1423
Included Angle
Included Angle
4034 Hammermill
Single Pass Max. Feed 5" x 5" Desired Approx. Grate Bar Product Top Size Group*
1
Speed RPM** 3" 1200 1200 1200 1200 900 900 900 900 900 900
Ag. Lime 1 " 4 1 " 2 3 " 4 3 " 4 7 " 8 1" 114" 112" 134"
1
16" 3 " 8
1 2 3 4 5 6 7 8 9 10
4" 4 3
8" 4 3 2
2"
4"
1"
112"
2"
4 3
4 4 4 3
1 2 4 4 3 2
2 6 6 4 4 4 8
2 2 1 4 3 4 7
1 1 1
4 4 6
Included Angle
Included Angle
22 1" 22 4" 3 " 22 112" 814 8 1 " 11 2" 11 2 3 " 22 3" 1612 4 Three sizes of grates are available for the 4034F fine grinding mill. They are 1 ", 1 " and 3 ". These are usually half and half for two adjacent sizes such as 8 4 8 1 8" and 14" or three equal groups of 18", 14", 38". These grates have included angles as follows: 18", 2, 14", 212 and 38", 3. The total number of grates used should total just under 180.
*The Grate Bars can be used in any combination as long as the total included angle adds up to 176. **Increasing RPM of mill decreases product size.
77
6.35 9.53 12.7 19.1 25.4 38.1 50.8 76.2 8 8 970 6 6 4 970 4 3 4 2 1 1 1 970 4 4 7 2 1 970 8 7 2 1 700 4 8 3 2 700 3 6 3 5 700 4 4 4 4 700 8 4 5 700 8 6 700 Grate Bar Size 25.4 mm 38.1 mm 50.8 mm 76.2 mm Included Angle 11 713 11 1423 11 11 11 11
Included Angle
4034 Hammermill
Single Pass Max. Feed 127 mm x 127 mm Desired Approx. Product Top Size Grate Bar (mm) (mm) Group* Ag. Lime 6.35 12.7 19.1 19.1 22.2 25.4 31.8 38.1 44.5 4.76 9.53 25.4 31.8 38.1 31.8 31.8 50.8 50.8 63.5 1 2 3 4 5 6 7 8 9 10 Grate BarsSize (mm) and Number Required Speed RPM**
6.35 9.53 12.7 19.1 25.4 38.1 50.8 76.2 4 4 1200 3 3 4 1200 2 3 4 1 2 1 1200 4 2 6 2 1 1200 4 6 2 1 900 4 4 4 1 900 3 3 4 4 900 2 4 3 4 900 8 4 4 900 7 6 900 Grate Bar Size 25.4 mm 38.1 mm 50.8 mm 76.2 mm Included Angle 22 814 11 1612 22 22 11 22
Included Angle
Three sizes of grates are available for the 4034F fine grinding mill. They are 3.18 mm, 6.35 mm and 9.53 mm. These are usually half and half for two adjacent sizes such as 3.18 mm and 6.35 mm or three equal groups of 3.18 mm, 6.35 mm and 9.53 mm. These grates have included angles as follows: 3.18 mm 2, 6.35 mm 212, and 9.53 mm 3. The total number of grates used should total just under 180. *The Grate Bars can be used in any combination as long as the total included angle adds up to 176. **Increasing RPM of mill decreases product size.
78
U AxBxCxDxExFxGxHxJ
FACTOR A
Surface % STPH Square Open Passing Opening Area A Sq. Ft. 4" 312" 3" 234" 212" 2" 134" 112" 114" 1" 75% 77% 74% 74% 72% 71% 68% 69% 66% 64% 63% 61% 59% 54% 51% 46% 45% 40% 45% 37% 41% 7.69 7.03 6.17 5.85 5.52 4.90 4.51 4.20 3.89 3.56 3.38 3.08 2.82 2.47 2.08 1.60 1.27 .95 .76 .58 .39 Deck Factor D
8" 3 4" 5 8" 1 2" 3 8" 1 4" 3 16" 1 8" 3 32" 1 16" 1 32"
60 65 1.40 1.55
FACTOR J (Efficiency)
95% 90% 85% 80% 75% 70% . . . . . . . . . . . . 1.00 . . . . . . . . . . . . 1.15 . . . . . . . . . . . . 1.35 . . . . . . . . . . . . 1.50 . . . . . . . . . . . . 1.70 . . . . . . . . . . . . 1.90
79
Diameter of Wire Gauge or Inches 22 20 19 18 17 16 10 9 8 7 6 5 5 4 3 3 Decimals of Inch .028 .034 .041 .047 .054 .062 .135 .148 .162 .177 .192 .207 .207 .225 .244 .244 .3125 .3125 .3125 .375 .375 .4375 .4375 .4375 .105 .135 .148 .177 Millimeters 0.71 0.86 1.04 1.19 1.37 1.57 3.43 3.76 4.11 4.49 4.88 5.26 5.26 5.71 6.20 6.20 7.94 7.94 7.94 9.52 9.52 11.1 11.1 11.1 2.67 3.43 3.76 4.49
NOTE: It is recommended that punched plate be used for 3" (76.2 mm) and larger screen openings. *Requires 3" (76.2 mm) opening. 14" (6.35 mm) wire Flat Top Weave Backing Screen.
80
Sieve Size Designation Openings* 3" 212" 2" 112" 114" 1" 3 " 4 1 " 2 3 " 8 1 " 4 Mesh** No. 4 No. 8 No. 10 No. 16 No. 20 No. 30 No. 40 No. 50 No. 80 No. 100 No. 200
Inches (Equivalents) 3.00 2.50 2.00 1.50 1.25 1.00 .750 .500 .375 .250 .187 .0937 .0787 .0469 .0331 .0232 .0165 .0117 .0070 .0059 .0029
Millimeters 76.2 63.5 50.8 38.1 31.7 25.4 19.1 12.7 9.52 6.35 4.76 2.38 2.00 1.19 .84 .59 .42 .297 .117 .149 .074
Permissible Variations in Size of Average Opening (Plus or Minus) COARSE SERIES 2% 2% 2% 2% 2% 3% 3% 3% 3% 3% FINE SERIES 3% 3% 3% 3% 5% 5% 5% 5% 6% 6% 7%
Permissible Variations in Size of Maximum Opening (Plus) 3% 3% 3% 3% 3% 5% 5% 5% 5% 5% 10% 10% 10% 10% 15% 15% 25% 25% 40% 40% 60%
Inches (Equivalents) .190 to .320 .175 to .280 .160 to .245 .145 to .210 .140 to .190 .135 to .177 .122 to .154 .094 to .122 .083 to .102 .063 to 0.83 .045 to .066 .0291 to .0433 .0268 to .0394 .0197 to .0276 .0150 to .0217 .0114 to .0165 .0091 to .0130 .0067 to .0100 .0045 to .0061 .0038 to .0049 .0018 to .0024
Millimeters 4.8 to 8.1 4.4 to 7.1 4.1 to 6.2 3.7 to 5.3 3.5 to 4.8 3.43 to 4.50 3.10 to 3.91 2.39 to 3.10 2.11 to 2.59 1.60 to 2.11 1.14 to 1.68 .74 to 1.10 .68 to 1.00 .50 to .70 .38 to .55 .29 to .42 .23 to .33 .170 to .253 .114 to .154 .096 to .125 .045 to .061
81
NOTE: *Opening is the space in the clear between the wires. **Mesh is measured from center to center of wire and means the number of openings in a lineal inch.
WASHING
INTRODUCTION
Clean aggregates are important to the construction industry. Yet producers of aggregates frequently are hard-pressed to meet all requirements for "cleanliness". Materials Engineers constantly strive to improve concrete and bituminous mixes and road bases. While hydraulic methods are the most satisfactory for cleaning aggregates to achieve the desired result, they are not always perfect. It is still necessary to accept materials on the basis of some allowable percent of deleterious matter. In the broadest terms, construction aggregates are washed to make them meet specifications. Specifically, however, there is more to the function of water in processing aggregates than mere washing. Among these 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 be perfect, and because some materials may require too much time, equipment, and water to make them conform to specifications, it is not always economically practical to use such materials. It is important, therefore, to test the source thoroughly beforehand to insure the desired finished aggregates can be produced at reasonable cost. The project materials engineer can be of immeasurable help in determining the economic suitability of the material, and generally must approve the source before production begins, anyway. Further, many manufacturers of washing equipment will examine and test samples to determine whether their equipment can do the job satisfactorily. No reputable equipment manufacturer wants to recommend his equipment where he has a reasonable doubt about its satisfactory performance on the job.
82
The ideal gradation is seldom, if ever, met in naturally occurring deposits. Yet the quality and control of these gradations is absolutely essential to the workability and durability of the end use. Gradation, however, is a characteristic which can be changed or improved with simple processes and is the usual objective of aggregate preparation plants. Crushing, screening and blending are methods used to affect the gradations of aggregates. However, even following these processes, the material may still require washing to meet specification as to cleanliness. Also, screening is impractical smaller than No. 8 mesh and hence, hydraulic separation, or classifying, becomes an important operation. Washing and classifying of aggregates can be considered in two parts, depending on the size range of material. Coarse material - generally above 3/8" (sometimes split at 1/4" or #4 mesh). In the washing process it usually is desired to remove foreign, objectionable material, including the finer particles. Fine aggregates - from 3/8" down. In this case it generally is necessary to remove dirt and silt while retaining sand down to 100 mesh, or even 200 mesh.
83
GRADATION OF AGGREGATES
This term is used to denote the distribution of sizes of the particles of aggregates. It is represented by a series of percentages by weight of particles passing one size of sieve but retained by a smaller size. The distribution is determined by a mechanical analysis performed by shaking the aggregate through a series of nested sieves or screens, in descending order of size of openings. Round openings are used for larger screens, square ones for the smaller sieves. Prescribed methods and prescribed openings of the screens and sieves have been established by the ASTM (American Society for Testing Materials). The normal series of screens and sieves is: 112", 34", 38", Numbers 4, 8, 16, 30, 50, 100, 200 mesh.
2 2 in (63 mm) 25 - 60
1 2 in. 1 in. 4 in. (37.5 mm) (25.0 mm) (19.0 mm) 0 - 15 0-5 0-5 0 - 15 35 - 70 90 - 100 95 - 100 100 100 100 90 - 100 90 - 100 95 - 100 100 100 90 - 100 90 - 100 100 20 - 55 0 - 15 35 - 70 20 - 55 40 - 85
100
0 - 15 35 - 70
0-5 10 - 30 0-5 10 - 30 0 - 10 10 - 40 25 - 60 20 - 55 0 - 15 20 - 55 90 - 100 100 40 - 70 85 - 100 0-5 0 - 15 0-5 0 - 10 0-5 0 - 10 0 - 15 10 - 30 0-5 0-5 0 - 10 0-5 0-5 0-5 0-5
85
SAND SPECIFICATIONS
Often referred to sand specifications are ASTM C-33 for concrete sand and ASTM C-144 for mason sand. These specifications are often written numerically and also shown graphically.
ASTM C-33
Sieve 3 8 No. 4 8 16 30 50 100 200 Limits % Passing 100 95-100 80-100 50-85 25-60 5-30 0-10 0-3 Center spec % Passing 100 97.5 90 67.5 42.5 17.5 5 1.5
ASTM C-144
Sieve 3 8 No. 4 8 16 30 50 100 200 Limits % Passing 100 100 95-100 70-100 40-75 10-35 2-15 0-10 Center spec % Passing 100 100 97.5 85 57.5 22.5 8.5 5
86
NOTES:
87
PERCENT PASSING
88
100 90 80 70 60 50 40 30 20 10 0 U.S. MM DECIMAL 3/8 9.5 0.375 1/4 6.3 0.250 4 4.75 0.187 6 3.35 0.132 8 2.36 10 12 2.0 1.7 .0937 .078.066
ASTM C-33
0 10
20
30
40
PERCENT PASSING
50
60
70
80
90
100 16 1.18 .0469 20 850 M .0331 30 600 .0234 40 425 .0165 50 300 .0117 70 212 80 180 100 150 140 106 .0041 200 75 .0029
ASTM C-144
100 0 90 10
80
20
70
30
PERCENT PASSING
60
40
PERCENT PASSING
50
50
40
60
30
70
20
80
10
90
0 U.S. 4 4.75 0.187 6 3.35 0.132 8 2.36 10 12 16 1.18 .0469 20 850 M .0331 30 600 .0234 40 425 .0165 50 300 .0117 70 212 80 180 100 150 140 106 .0041
89
MM DECIMAL
FM AND SE
The factor called Fineness Modulus (FM) which is commonly used, serves as a quick check that a given sample meets specifications without checking each sieve size of material against the standards set for a particular job. FM is determined by adding the cumulative retained percentages of sieve sizes #4, 8, 16, 30, 50 and 100 and dividing the sum by 100.
Sieve #4 #8 #16 #30 #50 #100 % Passing 97 81 59 36 15 4 % Retained 3 19 41 64 85 96 308 / 100 = 3.08 (FM)
Different agencies will require different limits on the FM. Normally, the FM must be between 2.3 and 3.1 for ASTM C-33 concrete sand with only 0.1 variation for all the material used throughout a certain project. The Sand Equivalent Test (SE) is more complex than the FM test. The "equivalent" refers to the equivalent quantities of fine vs coarse particles in a given sand sample. The test is performed by selecting a given quantity of a sand sample and mixing it in a special solution. The chemicals in the solution contain excellent wetting agents. These wetting agents will rapidly dissolve any deposits of semi-insoluble clays or plastic clays, which are clinging to the individual sand particles. After a specified period of agitation, either by hand or by machine, the sample is allowed to stand in a graduated tube for a specified time period. A weighted plunger is slowly lowered into the settled sand-solution mixture, and the depth to which the weight descends is noted from the graduations on the tube. A formula is supplied with the testing apparatus, and from that formula the "SE" is determined.
90
In general, the finer the sand, the deeper the weight will penetrate. The wetting agents, that dissolve the clay, make a seemingly coarse material much finer because the clays are now a separate, very fine product. This extra fine material acts as a lubricant and the weight will descend deeper in the sample. Because of this, it is possible that a sample with an acceptable FM is rejected for failure to pass the SE test.
91
Purpose: In the aggregate business the log washer is known best for its ability to remove tough, plastic soluble clays from natural and crushed gravel, crushed stone and ore feeds. The log washer will also remove coatings from individual particles, break up agglomerations, and reduce some soft, unsound fractions by a form of differential grinding. Design: The log washer consists of a trough or tank of all welded construction set at an incline (typically 610) to decrease the transport affect of the paddles and to increase the mass weight against the paddles. Each log or shaft (two per unit) is fitted with four rows of paddles which are staggered and timed to allow the paddles of each shaft to overlap and mesh with the paddles of the other shaft. The paddles are pitched to convey the material up the incline of the trough to the discharge end.
92
Kolbergs log washer design improves on the traditional design in that the paddles are set in a spiral pattern around the shaft instead of in a straight line as in competitive units. This design feature provides many benefits including: 1) Reduces intermittent shock loading of the log, 2) Keeps a portion of the mass in motion at all times thus reducing power peaks and valleys as well as overall power requirements, 3) Reduces wear and 4) Provides more effective scrubbing. Other important features of the Kolberg log washer include two (2) large tank drain/clean-out ports, rising current inlet, overflow ports on each side of the unit, cast ni-hard paddles with corrugated faces, readily available externally mounted lower end bearings and a custom designed and manufactured single input dual output gear reducer. Application: The majority of the scrubbing action performed by the log washer is accomplished by the abrading action of one stone particle on another, not by the action of the paddles on the material. Due to this and other feed material characteristics such as clay solubility, the capacity of a log washer is given in a fairly wide range. Normal practice is to follow the log washer with a screening device on which spray bars are used to remove fines and clay coatings on the stone.
93
Purpose: The coarse material washer is used to remove a limited amount of deleterious material from a coarse aggregate. This deleterious material includes shale, wood, coal, dirt, trash and some very soluble clay. A coarse material washer is often used as final wash for coarse material (typically -212" x +38") following a wet screen. Both single and double spiral units are available depending on the capacity required. Design: The coarse material washer consists of a long vertical sided trough or tank of all welded construction set at a 15 incline. The shaft(s) or spiral(s) of a coarse material washer begin with one double pitch spiral flight with replaceable ni-hard outer wear shoes and AR steel inner wear shoes. Following this single flight is a variable number of bolt-on paddle assemblies. Standard units include four (4) sets of paddle arms with ni-hard tips. Two (2) sets of arms replace one full spiral. The balance of the spiral(s) consists of double pitch spiral flights with replaceable ni-hard outer wear shoes and AR steel inner wear shoes.
94
Other important features of the Kolberg coarse material washer include a rising current manifold, adjustable full width overflow weirs, readily available externally mounted lower end bearing(s) and upper end bearing(s) and shaft mounted gear reducer with v-belt drive assembly (one drive assembly per spiral). Application: As previously noted, the number of paddle assemblies can be varied. The number of paddle assemblies installed on particular unit is dependent on the amount of water turbulence and scrubbing action required to suitably clean the feed material. As the number of paddles is increased, the operational characteristics of the unit change including increased scrubbing action, increased retention time, reduced capacity and increased power requirements.
NOTE: Two (2) motors required on twin units. 24" diameter unit offered only in single spiral configuration.
95
Purpose: Similar in design to the Series 6000 Coarse Material Washer, the blademill is used to pre-condition aggregates for more efficient wet screening. Blademills are generally used prior to a screening and washing application to break up small amounts of soluble mud and clay. Typical feed to a blademill is 212" x 0". Units are available in both single and double spiral designs depending on the capacity required. Design: The blademill consists of a long vertical sided trough or tank of all welded construction set at a variable incline (typically 0-4) depending on the degree of scrubbing or pre-conditioning required. The shaft(s) or spiral(s) of a blademill begin with one double pitch spiral flight with replaceable ni-hard outer wear shoes and AR steel inner wear shoes. Following this single flight is a combination of bolt-on paddle and flight assemblies, which can be varied, depending on the amount of scrubbing required. The flight assemblies include replaceable ni-hard outer wear shoes and AR steel inner wear shoes. The paddle assemblies are fitted with replaceable cast ni-hard paddle tips. Other important features of the Kolberg blademill include readily available externally mounted lower end bearing(s) and upper end bearing(s) and shaft mounted gear reducer with v-belt drive assembly (one drive assembly per spiral).
96
Application: The number of paddle and flight assemblies as well as the angle of operation can be varied dependent upon the amount of scrubbing or pre-conditioning required. Also, as the number of paddles or angle of operation is increased, the operational characteristics of the unit change including increased scrubbing action, increased retention time, reduced capacity and increased power requirements. Capacities/Specifications: Blademill capacity is indirectly a function of retention time. Each application will indicate a required period of time for effective washing, which actually determines the capacity of the unit. As a rule of thumb, a blademill can be expected to process in the range of a coarse material washer with respect to raking capacity in TPH and requires approximately 14 to 13 of the water required in a coarse material washer. If sufficient information is not available with regards to clay content and solubility, the lower end of the coarse material washer range should be used. Kolberg blademills are offered in single or twin screw configurations of the same size as coarse material washers.
97
98
In its strictest sense, however, classifying means that several sizes of sand products of equal specific gravity can be separated while rejecting slimes, silt, and similar deleterious substances. But sand particles are not necessarily always of the same specific gravity, so frequently both specific gravity and particle size affect the rate of settling. As a consequence, you cannot always estimate the probable gradation of the final products without preliminary tests on the material. Nor can you be sure of product quality without analysis and tests after processing. In any hydraulic classification of sand, the amount of fines retained with the final product will be dependent upon: 1. Area of settling basin. 2. Amount of water used. 3. Extent of turbulence in settling area. Obviously, the area of the settling basin generally will be fixed. Hence the amount and size of fines to be rejected will be determined by regulating the water quantity and turbulence.
99
Purpose: Fine material washers, also frequently called screw classifiers or screw dehydrators, are utilized to clean and dewater fine aggregates (typically 38" or -#4 mesh), fine tune end products to meet specifications and to separate out slimes, dirt and fines (typically -#100 mesh or finer). Available in both single and twin configurations, fine material washers are most often used after a sand classifying/blending tank or after a wet screening operation. Design: The fine material washer consists of an all welded tub set at an incline of approx. 18.5 (4:12 slope) and includes a full length curved bottom with integral rising current manifold designed to control fines retention and the water velocity within the pool. The lower end of the tub or tank is flared to provide a large undisturbed pool, which provides accurate material classification. Long adjustable weirs around the top of the sides and end of the tubs flared portion are designed to handle large volumes of slurry and to control the pool level for uniform overflow. Also incorporated into the design of the tub is a chase water line to clear the drain trough for better dewatering and an overflow flume.
100
The shaft(s) or spiral(s) of the fine material washer consist of a double pitch, solid flight spiral complete with AR steel inner wear shoes and urethane outer wear shoes to provide protection of the entire flight (cast ni-hard outer wear shoes are optional). Other important features of the Kolberg fine material washer include readily available externally mounted lower end bearing(s) and upper end bearing(s), shaft mounted gear reducer with v-belt drive assembly (one drive assembly per spiral) and center feed box with internal and external baffles to reduce the velocity of the material entering the fine material washer and reduce pool turbulence, enhancing fines retention. Application: Two important elements must be considered when sizing a fine material washer for a particular application: 1) calculation of overflow capacities and 2) calculation of sand raking capacity. Overflow capacity is critical to ensure that the unit has sufficient capacity to handle the water required for proper dilution of the feed material which allows for proper settling to occur and to produce the desired split point. The raking capacity of a fine material washer is governed by the fineness of the material to be dewatered. Generally speaking, the finer the material to be raked, the slower the spiral speed must be to ensure adequate dewatering and reduced pool turbulence. The following tables are provided to assist in the proper selection of a fine material washer. PERCENT SCREW SPEED vs. PERCENT FINES (in the product)
% SCREW SPEED (RPM) % PASSING 50 MESH % PASSING 100 MESH % PASSING 200 MESH
15 20 30 50
2 5 10 25
0 0 3 8
101
MODEL
*5024-25
50 37 25 12 75 55 38 18 100/200 75/150 50/100 25/50 175/350 130/260 85/170 45/90 200/400 150/300 100/200 50/100 250/500 185/370 125/250 60/120 325/650 250/500 165/330 85/170 400/800 300/600 200/400 100/200 475/950 355/710 235/475 120/240
100% 75% 50% 25% 100% 75% 50% 25% 100% 75% 50% 25% 100% 75% 50% 25% 100% 75% 50% 25% 100% 75% 50% 25% 100% 75% 50% 25% 100% 75% 50% 25% 100% 75% 50% 25%
32 24 16 8 25 19 13 7 21 15 12 6 17 13 9 5 16 12 8 4 14 11 7 4 13 9 5 3 11 8 5 3 11 8 5 3
500
225
125
*5030-25
550
275
150
5036-25
700/1200
325/600
175/300
5044-32
1500/2700 750/1300
400/750
5048-32
1650/2900 825/1450
450/825
5054-34
1800/3200 900/1600
525/900
5060-35
5066-35
5072-38
NOTE: Two (2) motors required on twin units. *24" & 30" dia. units offered only in single spiral configuration.
102
NOTE: All flows shown are in gpm. Bold italicized flows depict overflow rates required for 200, 150 & 100 mesh splits respectively. 112" 991 1024 1056
1200
4"
125 150
225
2"
275
4"
212" 1983 2048 2113 2568 2860 3380 2893 3478 3380 4030 3445
3600
92 95
175
229 236
325
564 583
700
98 119 132 156 134 160 156 186 159 189 164 197 167 206
244 296
400
601 731
750
514 572
750
1284
1500
330 390
450
814 962
825
676 579
825
1222 1046
1450
334 401
525
823 990
900
696 676
900
1257 1222
1600
390 465
550
962 1147
1000
806 689
950
398 473
625
2048 1771
2000
1281 1539
1250
2589 3111
2600
1212 1027
1200
2129 1804
2200
722 891
1304 1610
2636 3254
103
1267
2226
4453
(slurry) is introduced into the tank at the feed end. The slurry, which often comes from dredging or wet screening operations, flows toward the overflow end, and as it does, solids settle to the bottom of the tank. Weight differences between sand particles allow coarser material to settle first while lighter material progressively settles out further along the tank length.
PRINCIPLES OF SETTLING
The specific gravity of aggregates varies according to the nature of the minerals in the rock. "Bulk" specific gravity is used in aggregate processing and indicates the relative weight of the rock or sand, including the natural pores, voids and cavities, as compared to water (specific gravity = 1.0). In the case of fine aggregates, the specific gravity is about 2.65. As a consequence, the weight of grains of sand will be directly proportional to their volume. All grains of sand of a given size will therefore weigh the same, and the weight can be measured in relation to the opening of the sizing sieve. A second basic consideration is that of the density or specific gravity of the slurry itself. Dilution is usually expressed in percentages by weight of either the solid, or, of the water. Since the specific gravity of water is 1.00 and that of sand is assumed to be 2.65, a simple calculation will give the specific gravity, or density, of the slurry mixture.
For Solids SG 2.65-2.70 (sand, gravel, quartz, limestone): GPM Solids = TPH Solids x 1.5 4 For Slurry: GPM Slurry = TPH Slurry x SG Slurry To solve for Specific Gravity: TPH Slurry x 4 SG Slurry = GPM Slurry Example: Given: 10 TPH of Sand @ 40% Solids (by weight) Find: GPM and SG of Slurry Use this matrix to calculate your data
% Weight Water Solids Slurry 40 100 10 TPH SG 1.0 2.67 GPM
Fill in as follows: 1) Convert % Weight to decimel form: 40% = 0.40 2) TPH Slurry = TPH solids divided by 0.40 = 25 3) TPH Water = TPH Slurry - TPH Solids = 15 4) GPM Water = TPH Water x 4 = 60 5) GPM Solids = TPH Solids x 1.5 = 15 6) GPM Slurry = GPM Water + GPM Solids = 75 7) SG Slurry = TPH Slurry x 4/GPM Slurry = 1.33
% Weight Water Solids Slurry 60 40 100 TPH 15 10 25 SG 1.0 2.67 1.33 GPM 60 15 75
The tablulation can be solved for all unknowns if SG Solids and two other principal quantities are given. If GPM Slurry, % Solids and SG Solids are given, solve for 1 TPH and divide total GPM Slurry by resultant GPM Slurry to obtain TPH Solids. Rework tabulation with this figure to check the result. Percent Solids by Volume may be calculated directly from GPM column.
106
GPM column may also be extended to any other unit desired; 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 inherent in given quantities. 3) For sea water, use SG 1.026. In this case, the difference is appreciable. CONVERSION FACTORS
To Obtain TPH Short TPH Short TPH U.S. GPM U.S. GPM U.S. GPM Multiply Cu. Yd/Hr. Long TPH Metric TPH British GPM Cu. Ft./Min. Cu. Ft./Sec. By 1.35 1.12 1.1023 1.201 7.48 448.5 Based On Sand 100#/cu. ft., dry. 2240 lb. ton Kilo = 2.2046 lb.
The third consideration is that of viscosity. Viscosity can be compared to friction in that it is a resistance to movement between liquid particles and between solid and liquid particles. In a continuous process, such as in the production of fine aggregates, the slurry flows into and out of the classifying tank at a measurable rate, which determines its velocity of flow through the tank. The solids settle out, due to their weight, at a speed that is expressed as rate of fall or settling. It is the interrelationship between these two movements which governs the path of the falling particle.
FEED OVERFLOW DIAGRAM OF FORCES V O D A LA B C D E G PATH OF PARTICLE LC LD LE
LB
Settling From A Surface Current In the figure above, directions of the current and of the free fall of the particle are at right angles. The actual path of a falling particle is a parabola; the height of fall (D) and the length of horizontal travel (L) are determined by use of well-known formula. This is called settling from a surface current.
107
While a particle is in suspension, one force acts on it to make it fall, while others act to retard the fall. The force that acts downward is that of gravity (g). It has been brought out that viscosity of the liquid may retard the fall. The difference between free settling and hindered settling is a relative one between the factors causing a particle to fall and those retarding the fall. In free settling the downward component is much greater than those slowing up the fall are. In hindered settling the downward component is only slightly greater than those slowing the fall are. Apart from the multiple sizing, the scalping tank serves to eliminate the surplus water prior to discharge of product to a screw-type classifier. By so doing, the amount of water handled by the screw classifier can be regulated better for the mesh size of fines to be retained. It becomes apparent, then, that a water scalping tank will be followed by as many screw classifiers as there are sizes of sand products to be made. Adjustable weirs on the scalping tank regulate the rate and velocity of overflow to provide the size separations required. Clays, silt and slime which are lighter than the finest mesh sand, remain suspended in the water and are washed out over the tank weirs for discharge into a settling pond. In order to re-blend sand fractions into a specification product, settling stations are located along the bottom length of the tank. The best classifying occurs with more length to the classifying tank. It is recommended to use a minimum of a 28' tank. Shorter tanks will work when the material is very consistent in gradation and close to the product specification to be made. Build up or "silting in" of the classifying tank will occur as the specific gravity of the overflow slurry goes beyond 1.065. The ideal slurry is between 1.025 and 1.030. At this point maximum efficiency occurs. Additional water will carry away more fines unless the tank area is oversized.
108
G= 1.9
BY VO LU ME
1.9
SO LID SB YW EIG HT
FO R
DENSITY % SOLIDS BY VOLUME = 60 (G-1) 1.7 SPECIFIC GRAVITY SLURRY OR PULP (G)
SO LID S
1.8
1.8
FO R
1.6
1.6
1.5
1.5
1.4
1.4
1.3 EXAMPLE 1.2 FOR G = 1.25 DENSITY = 32% SOLIDS BY WT OR 15% SOLIDS BY VOL
1.3
1.2
1.1
1.1
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 KOLBERG MACHINES ARE RATED ON PERCENT SOLIDS BY WEIGHT.
109
Purpose: Classification is the sizing of solid particles (typically 38" or -#4 mesh) by means of settling. In classification, the settling is controlled so that the fines or undersize material will flow away with a stream of water or liquid, while the coarse or oversize material accumulates in a settled mass. By applying the principles of settling and classification in the classifying/ water scalping tank, the following functions are performed: 1) Reject undesirables remove clay, silts, slime and excess fine particles. 2) Separate desirable sand particles so that they can be controlled. 3) Reblend separated material into correct gradation specifications. 4) Production of two different specification products simultaneously and an excess product. 5) Remove excess water. Feed to a classifying tank is typically in the form of a sand and water slurry. The slurry feed can come from several sources, but is generally from a dredging or wet screening operation. CLASSIFYING TANKS ARE NECESSARY WHEN ANY ONE OF THE FOLLOWING CONDITIONS EXIST: 1) Feed material gradations fail to meet the allowable minimums or maximums when compared to the material 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 dredging operation.
110
Design: A classifying tank consists of an all welded tank of varying size ranging from 8' x 20' to 12' x 48'. The slurry feed is introduced into the tank through a feed box, which includes an integral curved liner for improved slurry flow control. As the slurry flows toward the discharge end of the tank, weight differences between sand particles allow coarser material to settle first while the lighter material settles progressively further down the tank. Clays, silt and slime which are lighter than the finest mesh sand remain suspended in the water and are washed out over the adjustable tank weirs for discharge into a settling pond. Sand fractions are then reblended into two specification products and an excess product, via settling stations (six to eleven depending on tank length) located along the bottom of the tank. Discharge valves (typically three) at each station serve to batch the sand into a collecting/ blending flume located below the tank.
VELOCITY CLASSIFICATION
FEED
A C B
111
Sand discharge is controlled via a controller (see section on Kolberg Spec-Select Classifying Tank Controllers) which receives a signal from an adjustable height sensing paddle located at each station. The sensing paddle controls the amount of material that accumulates at each station before a valve opens to discharge the sand and water slurry. The valves consist of self-aligning urethane dart valves and urethane seats providing uniform flow at the maximum rate, positive sealing and long service life. The urethane dart valve is connected to an adjustable down rod to ensure optimum seating pressure and provide leak resistant operation. The valves are activated by an electric/ hydraulic mechanism in response to signals received from the controller and sensing paddle. Once discharged, the slurry flows through product down pipes, which include urethane elbows for improved flow and wear into a collecting/blending flume for transport to the appropriate dewatering screw. The electric/hydraulic mechanism is mounted within a bridge that runs lengthwise with the tank. This system includes an electric/hydraulic pump, reservoir, accumulator, individual ball and check valves at each station and a toggle C switch box with 3-position A B switch for each individual valve providing maximum flexibility in trouble shooting and servicing the classifying tank. Other important features of the Kolberg classifying tank include stainless steel hydraulic tubing with O-ring face seal fittings, optional rising current cells to create hindered settling, optional recirculating pump to reduce overall water requirements and complete pre-wiring of the tank to a NEMA 4 junction box located near the end of the bridge.
112
Application: Several factors affect the sizing and application of a classifying tank. Among these are dry material feed rate, material density, feed gradation, product gradations or specifications desired, feed source, the amount of water entering the tank with the feed material and other material characteristics such as whether the material is crushed or natural. Of these factors, four items must be known to properly size a classifying tank: Feed rate (TPH)? Feed gradation? Feed source?..Conveyor? Dredge? Product gradations or specifications desired? Given the above, the classifying tank is sized based on its water handling capacity. The requirements for water in a classifying tank are to have approximately 10 GPM of water for every 1 TPH of total sand feed or 100 GPM of water for every 1 TPH of silt (-#200 mesh). The larger of these two figures and the desired mesh split to be produced within the tank are then used to size the classifying tank. This process allows for proper dilution of the sand so that the material will correctly settle in the tank for proper classification. The following table is provided to assist in the proper selection of a classifying tank.
8' X 20' 8' X 24' 8' X 28' 8' X 32' 10' X 24' 10' X 28' 10' X 32' 10' X 36' 10' X 40' 12' X 48'
9,600 11,800 14,000 16,300 16,000 18,000 21,000 24,000 27,000 39,000
61,000 73,000 86,800 99,600 125,000 145,000 160,000 180,000 200,000 270,000
2300 2800 3200 3500 3500 4100 4700 5300 5900 8100
1200 1400 1600 1800 1800 2100 2400 2700 3000 4200
700 800 900 950 950 1100 1250 1400 1550 2150
6 7 8 9 7 8 9 10 11 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.
113
114
MODEL WEIR LENGTH
1
2"
700
4"
134"
2"
214"
8' x 20' 8' x 24' 8' x 28' 8' x 32' 10' x 24' 10' x 28' 10' x 32' 10' x 36' 10' x 40' 12' x 48'
32' 40' 48' 56' 42' 50' 58' 66' 74' 80'
225 280 336 392 295 350 410 465 520 562
480
800
800
1400
1690 2120
3200
2225
2800
4400 5000 6000 7000 5250 6250 7250 8250 9250 10000
600
900
1000
1600
720
950
1200
1800
2550
3500
840
950
1400 1050
1100
630 750
1250
1520
2100
3570 4250
4700
1250 1450
1400
1800
2400
3500 4060
5300
880 990
1550
2080
2700
4930 5610
5900
1650 1850
2150
2380
3000
1110 1200
2660 2876
6290 6800
2000
4238
8390
NOTE: All flows shown are in gpm. Bold italicized flows depict overflow rates required for 200, 150 & 100 mesh splits respectively.
SPEC-SELECT CONTROLLERS
Purpose: Kolberg SpecSelect controllers are utilized in conjunction with a classifying tank to control the blending of the various sand fractions into one or two specification products plus an excess product. Spec-Select controllers are also a valuable source of information when trouble shooting or simply monitoring the activity occurring within a classifying tank. Design: Spec-Select controllers consist of an industrial quality solid-state PLC (Programmable Logic Controller) and/or PC (Personal Computer) housed in a NEMA 4 enclosure. Simple, touch-screen controls are used on all systems for the operator to set and adjust the electronic timers, proportioning the amount of material to be discharged from the three valves at each station of the classifying tank. EEPROM memory provides permanent storage of the screens in the display unit, which are used to create a user-friendly interface to the PLC, which actually controls the tank. Application: Two modes of controlling the tank discharge are utilized in conventional classifying tanks. The Spec-Seclect I (SSI) mode of operation is the simplest method to operate a classifying tank and is the same in theory as the manual splitter box type classifying tanks. It is an independent control of each station by a percentage method to determine the amount of material discharged to each of the three product flumes. The system operates on a 10-second cycle that is repeated over and over from product A to B to C. The mode of operation works best in a fairly consistent pit where the feed gradation does not vary too much. Monitoring of the product gradations informs the operator of variances in the feed. Changes to the percentage settings at each station can be made quickly at the controller to maintain the product specification. 115
The Spec-Select II (SSII) mode of operation is a dependent method of operation utilizing minimum and maximum timer settings at each station to control the material discharge and ensure that product specifications are met on a consistent basis. This system not only controls the discharge valves at each station but also controls all of the settling stations relative to each other. The minimum and maximum timer settings are determined by the gradation of the material settling out at each station and relating this to the product specification limits. In effect, the SSII mode of operation is making batches of specification sand continuously. Each A or B valve at a given station discharges sand on a time basis between its minimum and maximum timer settings. No valve can begin a new batch until every other valve has discharged at least its minimum in the present batch being made. When a valve reaches its maximum timer setting and one or more of the other valves for that product have not yet met their minimum settings, the controller automatically directs the material to one of the other product valves and flumes. It is important to remember, in this mode of operation, the potential to waste or to direct sand to a non-spec product where it is not desired is increased and should be carefully considered when operating a tank by this method. This mode of operation is typically used when the feed gradation and/or feed rate vary widely. KOLBERG OFFERS THREE MODELS OF SPEC-SELECT CLASSIFYING TANK CONTROLLERS:
Spec-Select I Spec-Select II Spec-Select III
Yes No No
Yes No No
SSI & SSII Color PC operator interface with PLC control Yes Yes Yes
NOTE: Each controller upgrade (i.e. SSI >>, SSII >>, SSIII) also incorporates additional feedback or monitoring screens to assist the operator in fine tuning the control of the classifying tank discharge.
116
NOTES:
117
Purpose: Screening/washing plants are utilized to rinse and size up to three stone products while simultaneously washing, dewatering and fine tuning a single sand product. Specific stone product gradations can typically be met with the use of blending gates between the screen overs chutes while sand product gradations are adjusted with screw speed and water overflow rates. Design: Series 1800 screening/washing plants consist of a heavy duty Kolberg-Pioneer two or three deck, 10 wet screen (horizontal optional) mounted above a Kolberg fine material washer on either a semi-portable skid support structure or a heavy duty portable chassis. Important features of the Kolberg screening/ washing plant include the capability to fit three radial stacking conveyors under the screen overs chutes, complete water plumbing with single inlet connection and wide three sided screen access platform as well as all the features of the industry leading Pioneer screen and Kolberg fine material washer. Application: Review of the feed material gradation, products desired and TPH to be processed will determine the screen and screw combination best suited for the application.
118
Screen Size (triple deck, 10) Optional JCI Horizontal Fine Material Washer Size Fine Material Washer Capacity (@ 100% screw speed) Water Requirements (up to maximum, dependent on feed material gradation) OPTIONAL EQUIPMENT: Skid Frame vs. Portable Chassis Feed/Slurry Box Wear Liners Screen Cloth Wedge Bolts (for screen cloth retention) Hydraulic Screen Adjust (portable plants only) Quickstop (screen) Electrical Package Horizontal Screen
6' x 16' 6' x 16' 36" twin 200 TPH 1,200 GPM
6' x 20' 6' x 20' 44" twin 350 TPH 2,700 GPM
NOTE: Skid plants can be configured to include a number of different screen and screw combinations. For further capacity or specification information on Kolberg-Pioneer screens and fine material washers, see the corresponding sections of this book relating to these pieces of equipment.
119
120
As material flows over a vibrating screening surface, it tends to develop fluid-like characteristics. The larger particles rise to the top while the smaller particles sift through the voids and find their way to the bottom of the material bed. This phenomenon of differentiation is called stratification. Without stratification of the material, there would be no opportunity for the small particles to get to the bottom of the material bed and pass through the screen apertures causing separation of material by size. After the material has been stratified to allow the passage of throughs, the apertures are then blocked with oversize particles that were above the fines in the material bed before passage of more fines can occur, the bed must be restratified so the fines are again at the bottom of the bed and available for passage. Thus the process must be repeated successively until all fines are passed. Potential occurrences that can prevent successful screening include: 1. The arrival of several particles at an aperture, with the result that none succeed in passing even though all are undersize. 2. Oversize particles plugging the openings so that undersize cannot pass though. 3. Undersize particles blinding the apertures by sticking to the screening media which reduces the opening thus preventing passage of undersize particles. 4. Oblique impact of near-size particles bouncing off the sides of the aperture reducing efficiency.
Figure 1
121
2. Adding a spray system to increase the moister content of the material being screened. The water breaks down the fine material and flushes the fines though the screening media. 3. The use of slotted opening wire to increase percent of open area and reduce the number of wires which material can build up on. The slots also increase the distance material has to bridge before blinding occurs in one direction. 4. End-tension decks also increase the percent of open area in two ways. The wire itself has greater open area with fewer cross wires. The deck frame has fewer rails supporting the wire which blocks openings reducing open area. End-tension wire has a higher tension smaller diameter wire which cuts through sticky material. End-tension wires also can flex independently between cross wires vibrating like guitar strings preventing material from sticking to the wire. 5. Z-wire also has increased open area over standard weave wire. As material sticks to the wire the mass increases to a point were defection of the wire causes the sticky material to crumble and separate from the wire.
124
Plug Configuration 3 Plugs Each Wheel 3 4" Approximately 2 Plugs Each Wheel 11/16" Approximately 1 Plug Each Wheel 5 8" Approximately No Plugs Each Wheel 9 16" Approximately Minimum Stroke
4" - 114"
RPM of Screen Very Slow 740 RPM Slow 3 4" to 114" 785 RPM Fast 3 4" to 114" 830 RPM Very Fast 875 RPM
Timing Angle 45 - 55 40 - 50
35 - 45
30 - 40
125
GAL. PER GAL. PER GAL. PER SCREEN SCREEN SCREEN AT 20 PSI AT 30 PSI AT 40 PSI 4" ORIFICE 14" ORIFICE 14" ORIFICE
8203-38 8202-38 7203-38 7202-38 6203-32 6202-32 6163-32 6162-32 5163-26 5162-26 5143-24 5142-24
6 6 6 6 6 6 5 5 5 5 4 4
6 6 6 5 5 4 -
5 5 5 5 5 5 4 4 4 4 4 4
17 11 17 11 17 11 14 9 14 9 12 8
425 275 374 242 323 209 266 171 210 135 180 120
3017 1952 2655 1718 2293 1484 1889 1214 1491 959 1278 852
3655 2365 3216 2081 2778 1797 2288 1471 1806 1161 1548 1032
4250 2750 3740 2420 3230 2090 2660 1710 2100 1350 1800 1200
STANDARD NOZZLE ORIFICE SIZE 14" 20 PSI at Nozzle capacity is 7.1 gallons per minute 30 PSI at Nozzle capacity is 8.6 gallons perminute 40 PSI at Nozzle capacity is 10 gallons per minute 8' Spray Pipe has 25 Nozzles per pipe 7' Spray Pipe has 22 Nozzles per pipe 6' Spray Pipe has 19 Nozzles per pipe 5' Spray Pipe has 15 Nozzles per pipe
126
NOTES:
127
FINISHING SCREENS
The JCI finishing screen maximizes screening efficiency and productivity in fine separation applications by utilizing a reduced stroke and a higher frequency that provides an optimal sifting action. Adjustable stroke length (Amplitude) min 38" to max 12" (Stroke reduced by removing weight plugs.) Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degrees Operating speed range . . . . . . . . . . . . . . . . . . . . . . . . 875-1075 rpm Maximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 8" Maximum top deck opening . . . . . . . . . . . . . . . . . . . . All model screens = 2" Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . 24" Cloth support bar thickness (Rail thickness) . . . . . . . 38" Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24" Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 14" Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 5' & 6' = 516" 7' = 14" Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . 14" Discharge lip liner thickness (AR plate) . . . . . . . . . . . 14" Bearing size: 5142-24FS & 5143-24FS . . . . . . . . . . . . 120 mm 5162-26FS & 5163-26FS. . . . . . . . . . . . 130 mm 6162-32FS & 6163-32FS. . . . . . . . . . . . 160 mm 6202-32FS & 6203-32FS. . . . . . . . . . . . 160 mm 7202-38FS & 7203-38FS. . . . . . . . . . . . 190 mm 8202-38FS & 8203-38FS. . . . . . . . . . . . 190 mm
128
STANDARD SCREENS
The standard series are best suited for the widest array of applications ranging from fine to coarse material separation applications.
Adjustable stroke length (Amplitude) . . . . . . . . . . . . . (Stroke reduced by removing weight plugs.) Adjustable stroke angle (Timing angle). . . . . . . . . . . . Operating speed range . . . . . . . . . . . . . . . . . . . . . . . . Maximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum top deck opening . . . . . . . . . . . . . . . . . . . . Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . Cloth support bar thickness (Rail thickness) . . . . . . . Deck cross-member spacing . . . . . . . . . . . . . . . . . . . Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . Discharge lip liner thickness (AR plate) . . . . . . . . . . . Bearing size: 5142-24 & 5143-24 . . . . . . . . . . . . . . . . 5162-26 & 5163-26. . . . . . . . . . . . . . . . 6162-32 & 6163-32. . . . . . . . . . . . . . . . 6202-32 & 6203-32. . . . . . . . . . . . . . . . 7202-38 & 7203-38. . . . . . . . . . . . . . . . 6202-32LP & 6203-32LP . . . . . . . . . . . 7202-38LP & 7203-38LP . . . . . . . . . . . 8202-38W & 8203-38W . . . . . . . . . . . .
min 58" to max 34" 30 to 60 degrees 675-875 rpm 10" 514, 516 & 616 = 5" 620, 720 & 820 = 4" 18" 3 8" 24" 1 4" 1 4" 1 4" 1 4" 120 mm 130 mm 160 mm 160 mm 190 mm 160 mm 190 mm 190 mm wide profile
129
Adjustable stroke length (Amplitude) . . . . . . . . . . . . . Adjustable stroke angle (Timing angle). . . . . . . . . . . . Operating speed range . . . . . . . . . . . . . . . . . . . . . . . . Maximum feed size* . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum top deck opening . . . . . . . . . . . . . . . . . . . . Maximum drop of feed* . . . . . . . . . . . . . . . . . . . . . . . Cloth support bar thickness . . . . . . . . . . . . . . . . . . . . Deck cross-member spacing . . . . . . . . . . . . . . . . . . . Top deck cross-member spacing . . . . . . . . . . . . . . . . Side Plate thickness* . . . . . . . . . . . . . . . . . . . . . . . . . Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . Discharge lip liner thickness (AR plate) . . . . . . . . . . . Bearing size: 5142-24 & 5143-24 . . . . . . . . . . . . . . . . 5162-26 & 5163-26. . . . . . . . . . . . . . . . 6162-32MS . . . . . . . . . . . . . . . . . . . . . . 6202-32MS . . . . . . . . . . . . . . . . . . . . . . 7202-38 & 7203-38. . . . . . . . . . . . . . . .
min 916" to max 34" 30 to 60 degrees 675-875 rpm 14" All model screens = 5" 16" 3 8" 24" 5': 6" WF 6': 8" WF 5 16" 5 16" 1 4" 3 8" on 4" to 24" lips 120 mm 130 mm 160 mm 160 mm 190 mm
130
Adjustable stroke length* (Amplitude) . . . . . . . . . . . . (Stroke reduced by removing weight plugs.) Adjustable stroke angle (Timing angle). . . . . . . . . . . . Operating speed range* . . . . . . . . . . . . . . . . . . . . . . . Maximum feed size* . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum top deck opening* . . . . . . . . . . . . . . . . . . . Maximum drop of feed* . . . . . . . . . . . . . . . . . . . . . . . Cloth support bar thickness (Rail thickness bottom deck) . . . . . . . . . . . . . . . . . Deck cross-member spacing . . . . . . . . . . . . . . . . . . . Top deck cross-member spacing . . . . . . . . . . . . . . . . Side Plate thickness* . . . . . . . . . . . . . . . . . . . . . . . . . Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . Discharge lip liner thickness (AR plate) . . . . . . . . . . . Bearing size: 5142-26HS . . . . . . . . . . . . . . . . . . . . . . 5162-32HS . . . . . . . . . . . . . . . . . . . . . . 6162-38HS . . . . . . . . . . . . . . . . . . . . . .
min 34" to max 78" 30 to 60 degrees 575-775 rpm 18" All model screens = 6" 12"
8" 24" 5': 8 WF 6': 10 WF 5 16" 5 16" 1 4" 3 8" on 4" to 24" lips 130 mm 160 mm 190 mm
3
131
132
NOTES:
133
4 3 16
Maximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum top deck opening . . . . . . . . . . . . . . . . . . . . Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . Cloth support bar thickness (Rail thickness) . . . . . . . Deck cross-member spacing . . . . . . . . . . . . . . . . . . . Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . Discharge lip liner (AR plate) . . . . . . . . . . . . . . . . . . . Bearing size: 6202 & 6203 . . . . . . . . . . . . . . . . . . . . . 7202 & 7203 . . . . . . . . . . . . . . . . . . . . . 8202 & 8203 . . . . . . . . . . . . . . . . . . . . .
RPM 1000 1150 8" 2" 18" 3 8" 24" 3 8" 3 8" 3 8" 3 8" 140 mm 140 mm 160 mm
134
Standard stroke length (Amplitude) . . . . . . . . . . . . . . 38" stroke Standard operating speed . . . . . . . . . . . . . . . . . . . . . . 850 rpm Optional stroke and speed relationships . . . . . . . . . . . Stroke (in.) RPM 3 1200 16 1 1050 4 1 750 2 Maximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum top deck opening . . . . . . . . . . . . . . . . . . . . Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . Cloth support bar thickness (Rail thickness) . . . . . . . Deck cross-member spacing . . . . . . . . . . . . . . . . . . . Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . Discharge lip liner (AR plate) . . . . . . . . . . . . . . . . . . . Bearing size: 6202 & 6203 . . . . . . . . . . . . . . . . . . . . . 7202 & 7203 . . . . . . . . . . . . . . . . . . . . . 8202 & 8203 . . . . . . . . . . . . . . . . . . . . . 8" 4" 18" 3 8" 24" 3 8" 3 8" 3 8" 3 8" 140 mm 140 mm 160 mm
135
JCI
20 15
SCREENS (Multi-Slope)
10 7 .5 0
0 0
PATENT APPLIED FOR
JCI COMBO screens combine the advantages of both an inclined screen and a horizontal screen. The top deck of the screen is equipped with incline panel sections that begin with a 20-degree section, flatten to a 10 degree section, and the remaining deck area is at zero degrees. The second deck begins at 15 degrees, flattens to 7.5 degrees, and the remaining deck is also at zero. The entire bottom deck is horizontal. By installing sloped sections at the feed end, material bed depth is reduced since gravity will increase the travel speed of the material. This reduced bed depth minimizes spillover, and enables fine particles to stratify through the coarser particles and onto the screening surface much faster, where it can then find more opportunities to be passed through screen openings. This design also enables fines to be introduced to the horizontal bottom deck faster, which increases the bottom deck screening capacity, or bottom deck factor used in the VSMA screen calculation. JCI has also designed a punch plate section into the feed plate itself, thereby increasing the total screening area by an additional 10%. This punch plate will remove a high percentage of fine particles before they are even introduced to the actual screen deck, thereby increasing production volumes. The coarse near size and over size particles that are not initially separated on the middle and top decks gradually slow down as the deck panels flatten out to the horizontal section towards the discharge end of the screen. This materials reduced travel speed, combined with the optimum angle of trajectory in
136
relationship to the screen opening, provides a high screening efficiency that oval motion horizontal screens have built their reputation on. The COMBO screen is also the only multi-slope design that features a triple shaft design. This design provides an optimal oval screening motion that has proven effective over decades of success in the companys traditional flat screen design. In addition to the features of the COMBO design, producers will also benefit by having the ability to adjust stroke length, stroke angle, and RPM speed to best suit the conditions of the application. The end result is a machine that: 1) Provides increased feed production by as much as 20% over standard flat or incline screens; 2) Maintains or improves the screening efficiency of separation found on horizontal screens; 3) Reduces material spillover at the feed end from high volumes or surges of feed material; 4) Improves the bottom screen decks utilization, thereby increasing volume and efficiency. Although not as portable as the traditional horizontal screens, the COMBO design will be an ideal screen for a variety of both scalping and product sizing applications. The design is especially well suited for accepting large volumetric feed surges, deposits containing a high percentage of fines that must be removed, installations where screening capacity must be increased within the same structural or mounting footprint, or in closed circuit with crushers. JCI COMBO screens are available in both a standard duty and finishing duty three deck configurations and are currently available in 6x20 and 8x20 sizes. JCI COMBO screens feature huck-bolt construction, incline deck panels that slope form 20 to zero degrees, adjustable stroke amplitudes, a hinged tailgate rear section for maintenance access, and a perforated feed box for additional screening area. COMBO screens can be installed with either standard wire cloth or urethane/rubber deck panels.
137
Adjustable stroke length (Amplitude) . . . . . . . . . . . . . (Stroke reduced by removing weight plugs.) Adjustable stroke angle (Timing angle). . . . . . . . . . . . Operating speed range . . . . . . . . . . . . . . . . . . . . . . . . Maximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum top deck opening . . . . . . . . . . . . . . . . . . . . Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . Cloth support bar thickness (Rail thickness) . . . . . . . Deck cross-member spacing . . . . . . . . . . . . . . . . . . . Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . Discharge lip liner thickness (AR plate) . . . . . . . . . . . Bearing size: 5142-24 & 5143-24 . . . . . . . . . . . . . . . . 5162-26 & 5163-26. . . . . . . . . . . . . . . . 6162-32 & 6163-32. . . . . . . . . . . . . . . . 6202-32 & 6203-32. . . . . . . . . . . . . . . . 7202-38 & 7203-38. . . . . . . . . . . . . . . . 6202-32LP & 6203-32LP . . . . . . . . . . . 7202-38LP & 7203-38LP . . . . . . . . . . . 8202-38W & 8203-38W . . . . . . . . . . . .
min 58" to max 34" 30 to 60 degrees 675-875 rpm 10" 514, 516 & 616 = 5" 620 & 720 = 4" 18" 3 8" 24" 1 4" 5' & 6' = 14" 7' = 14" 1 4" 120 mm 130 mm 160 mm 160 mm 190 mm 160 mm 190 mm 190 mm
138
A, the calculated capacity per square foot of screen area in tons per hour. B = Basic capacity per square foot in tons per hour (One ton = 2000 pounds) S = Incline factor D = Deck factor V = Oversize factor H = Halfsize factor T = Slot factor K = Material condition factor Y = Spray factor P = Shape factor O = Open area factor W = Weight factor F = Efficiency factor There are other influences but which materially affect screen operation. We have assembled this data and weighted it in accordance with our experience. The additional factors we are suggesting are: TYP = STR = TIM = RPM = NEA = BED = Type of stroke factor Stroke length factor Timing angle factor Revolutions per minute factor Near size factor Bed depth factor
The screen capacity formula with 6 new factors above now becomes: A = B * S * D * V * H * T * K * Y * P * O * W * F * TYP * STR * TIM * RPM * NEA * BED 139
S = Incline factor
140
D = Deck factor
141
T = Slot factor
142
Y = Spray factor
143
P = Shape factor
144
W = Weight factor
F = Efficiency factor
145
146
147
148
149
150
151
152
153
154
155
156
157
WD = Width factor
158
NOTES:
159
KOLBERG SCREENS
INTRODUCTION
Vibrating screens are used to separate a mixture of sizes of materials into categories of sizes. Sorting is done by passing the mixed material along a surface having uniform openings. Those particles small enough to pass through the openings are called the undersize product and those particles too large to pass through the openings are called the oversize product of those particular openings. The surface having the openings is usually formed of woven wire and is called screen cloth. Coarse sorting is sometimes done on a steel plate surface having relatively large holes either cut or punched in it. These wire cloths or punched plate surfaces are held in superimposed frames called decks. Vibrating screens may have one, two, three or four decks. The undersize of each deck falls to that below it for additional sorting. The decks are held in a box-like structure. The box is mounted on a rotating shaft made to vibrate. The vibration is induced by an eccentricity cut into the shaft or by counterweights mounted on the ends of the shaft. Each revolution of the powered shaft lifts the box and its screening surfaces and at the same time moves the entire assembly forward. This causes the material on the decks to flow in a bouncing manner from the feed ends of the decks to the discharge ends. Suitable chutes and hoppers gather the several sizes of products produced.
160
U AxBxCxDxExFxGxHxJ
FACTOR A
Surface % STPH Square Open Passing Opening Area A Sq. Ft. 4" 312" 3" 234" 212" 2" 134" 112" 114" 1" 75% 77% 74% 74% 72% 71% 68% 69% 66% 64% 63% 61% 59% 54% 51% 46% 45% 40% 45% 37% 41% 7.69 7.03 6.17 5.85 5.52 4.90 4.51 4.20 3.89 3.56 3.38 3.08 2.82 2.47 2.08 1.60 1.27 .95 .76 .58 .39 Deck Factor D
8" 3 4" 5 8" 1 2" 3 8" 1 4" 3 16" 1 8" 3 32" 1 16" 1 32"
60 65 1.40 1.55
FACTOR J (Efficiency)
95% 90% 85% 80% 75% 70% . . . . . . . . . . . . 1.00 . . . . . . . . . . . . 1.15 . . . . . . . . . . . . 1.35 . . . . . . . . . . . . 1.50 . . . . . . . . . . . . 1.70 . . . . . . . . . . . . 1.90
161
Kolberg Series 70: All series 70 screens are two bearing inclined screens and include base frame with C spring suspension and electric motor drives. These screens are a medium-light duty screen and typically are used to size material down to #4 mesh and up to 3" maximum. They are available in a range of sizes from 2' x 4' to 5' x 12'. Series 71 is a Conventional Screen and is available in single, double or triple deck configurations. Each deck has side tensioned cloth. They operate at an incline of approximately 15. SINGLE DECK
Model 71-1D244 71-1D366 71-1D368 71-1D486 71-1D488 Size 24" x 4' 36" x 6' 36" x 8' 48" x 6' 48" x 8' Speed 15-1700 14-1600 14-1600 14-1600 13-1500 Motor 2 HP 3 HP 3 HP 3 HP 5 HP
DOUBLE DECK
Model 71-2D366 71-2D486 71-2D488 71-2D4810 Size 36" x 6' 48" x 6' 48" x 8' 48" x 10' Speed 14-1600 13-1500 13-1500 11-1300 Motor 3 HP 5 HP 7-1/2 HP 10 HP
TRIPLE DECK
Model 71-3D366 71-3D488 162 Size 36" x 6' 48" x 8' Speed 13-1500 11-1300 Motor 5 HP 10 HP
Series 72 is a Desander and is available in a double deck configuration. The top deck cloth is side tensioned and the bottom deck cloth is end tensioned harp wire type. They operate at an incline of 15 to 50. DOUBLE DECK
Model 72-2D488 72-2D4810 72-2D4812 72-2D6010 72-2D6012 Size 48" x 8' 48" x 10' 48" x 12' 60" x 10' 60" x 12' Speed 11-1300 11-1300 11-1300 11-1300 11-1300 Motor 7-1/2 HP 10 HP 10 HP 10 HP 10 HP
Series 77 is a Vibrating Grizzly and is available in single or double deck configurations. Grizzly Bars are available in fixed or adjustable configurations. Single deck configurations include grizzly bars only. Double deck configurations include grizzly bars on the top deck and side tensioned screen cloth on the bottom deck. Coil impact springs are mounted inside of the C springs. They operate at an incline angle of approximately 15. SINGLE DECK
Model 77-1DG-(F or A) 366 77-1DG-(F or A) 488 Size 36" x 6' 48" x 8' Speed 13-1500 11-1300 Motor 7-1/2 HP 10 HP
DOUBLE DECK
Model 77-2DG-(F or A) 488 77-2DG-(F or A) 4810 Size 48" x 8' 48" x 10' Speed 11-1300 11-1300 Motor 15 HP 15 HP
163
Kolberg Portable Screening Plants: There are four different models of Kolberg portable screening plants Models 241, 271, 291 and 391. These plants are all hydraulic with Seal-Lok, O-ring fittings and include self-contained diesel engine power units. The hopper design features a vertical front wall and 70 rear and side walls for improved material flow. The screen is a two bearing design with double row spherical roller bearings for long service life. Screen adjustments can be made for improved screen efficiency. These adjustments include: adjustable screen speed, adjustable throw, adjustable screen angle and reversal of screen rotation. These plants are medium duty plants with scalping grizzly set at 6" spacing. Applications for these plants include: sand and gravel, sand washing, recycle, topsoil, compost, ash, peat, sludge, aglime, clay, coal and aggregates.
Model 241: This plant is designed for the lower TPH applications. It includes an 8 cu.yd. hopper, 30" belt feeder, 24" conveyor and 4'x6' two deck screen as standard. Model 271: This plant is the most versatile size and can generally be used in most applications. It includes a 9 cu.yd. hopper, 36" belt feeder, 30" conveyor and 4'x8" two deck screen as standard. Screen angle can be adjusted on-the-fly. Model 291: This plant is designed for the larger TPH application. It includes a 12 cu.yd. hopper, 42" belt feeder, 42" conveyor and 5'x12' two deck screen. Screen angle can be adjusted on-the-fly.
164
Model 291
Model 391-T
Model 391
Model 391: This plant is designed for optimum portability with three on-board discharge conveyors that quickly and easily fold for travel. This plant includes a 12 cu.yd. hopper, 42" belt feeder, 36" conveyor, 5'x12' two deck screen, two (2) 24" side discharge conveyors and 42" fines discharge conveyor.
Std. Screen Size 4' x 6', 2 deck Optional Screen 4' x 8', 2 deck Size On-Board Conveyors Power n/a 62 HP
n/a 165 HP
165
Screen Size Opening for the Loader Bucket Loader Bucket Cu. Yd. Landing Gear Optional Field Replaceable Conveyor
710 KDS 10'-0" x 6'-812" 12'-0" 3 to 5 Hydraulic 48" x 35' Fines Conveyor
N/A
166
NOTES:
167
CONVEYORSINTRODUCTION Belt conveyors are designed to carry material via the shortest distance between the loading and unloading points. When required, belt conveyors can operate continuously, without loss of time and are capable of handling tonnages of bulk materials that would be more costly and often impractical to transport by other means. This often avoids confusion, delays, and safety hazards of rail and motor traffic in plants and other congested areas.
Choosing the right conveyor starts with looking at the five basic considerations: material characteristics, conveyor length and discharge height, TPH feed, conveyor width and HP requirements. 1. Material Characteristics a. Variables include: Particle Shape, Particle Size, Moisture, Angle of Repose, Lump Size & % Fines and Weight. Characteristics normally used as a rule of thumb include: 100 lbs. per cubic foot density, 37 degree angle of repose and less than 25% of a max. 3" lump.
RECOMMENDED MAXIMUM ALLOWABLE INCLINE FOR BULK MATERIALS
Material Alumina . . . . . . . . . . . . . . . Ashes, Coal, Dry, 1/2" and Under . . . . . . . . . . . . Ashes, Coal, Wet, 1/2" and Under . . . . . . . . . . . . Ashes, Fly. . . . . . . . . . . . . . Bauxite, Ground, Dry . . . . . Bauxite, Mine Run . . . . . . . Bauxite, Crushed 3" and Under . . . . . . . . . . . . Borax, Fine . . . . . . . . . . . . . Cement, Portland . . . . . . . . Charcoal . . . . . . . . . . . . . . . Cinders, Blast Furnace . . . . Cinders, Coal . . . . . . . . . . . Coal Bituminous, Run of Mine . Bituminous, Fines Only . . Bituminous, Lump Only . . Anthracite, Run of Mine . . Anthracite, Fines . . . . . . . Anthracite, Lump Only . . . Anthracite, Briquettes. . . . CokeRun of Oven . . . . . . Coke, Breeze . . . . . . . . . . . ConcreteNormal . . . . . . . ConcreteWet (6" Slump) . . . . . . . . . . . . ChipsWood . . . . . . . . . . Cullet . . . . . . . . . . . . . . . . . Dolomite, Lumpy . . . . . . . . GrainsWhole . . . . . . . . . GravelWashed . . . . . . . . Gravel and Sand. . . . . . . . . Gravel and Sand Saturated . . . . . . . . . . . . . Gypsum, Dust Aerated . . . . Angle Incline 10-12 20-25 23-27 20-22 20 17 20 20-25 23 20-25 18-20 20 18 20 16 16 20 16 12 18 20 15 12 27 20 22 15 15 20 12 23 % Grade Material 17.6-21.2 Gypsum, 1/2" Screening . . . Gypsum, 1-1/2" to 3" 36.4-46.6 Lumps . . . . . . . . . . . . . . . . EarthLoose and Dry. . . . . 42.4-50.4 Lime, Ground, 1/8" 36.4-40.4 and Under . . . . . . . . . . . . . 36.4 Lime, Pebble . . . . . . . . . . . . 30.6 Limestone, Crushed . . . . . . Limestone, Dust . . . . . . . . . 36.4 Oil Shale . . . . . . . . . . . . . . . 36.4-46.6 OresHardPrimary 42.4 Crushed. . . . . . . . . . . . . . . 36.4-46.6 OresHardSmall 32.5-36.4 Crushed Sizes . . . . . . . . . . 36.4 OresSoftNo Crushing Required . . . . . . 32.4 Phosphate Triple Super,. . . . 36.4 Ground Fertilizer . . . . . . . . 28.6 Phosphate Rock, 28.6 Broken, Dry . . . . . . . . . . . . 36.4 Phosphate Rock, Pulverized 28.6 Rock, Primary Crushed . . . . 21.3 Rock, Small Crushed Sizes . 32.4 SandDamp. . . . . . . . . . . . 36.4 SandDry . . . . . . . . . . . . . 26.8 Salt . . . . . . . . . . . . . . . . . . . Soda Ash (Trona) . . . . . . . . 21.3 Slate, Dust. . . . . . . . . . . . . . 50.9 Slate, Crushed, 1/2" 36.4 and Under . . . . . . . . . . . . . 40.4 Sulphate, Powder . . . . . . . . 26.8 Sulphate, Crushed1/2". . . 26.8 and Under . . . . . . . . . . . . . 36.4 Sulphate, 3" and Under . . . . TaconitePellets . . . . . . . . 21.3 Tar Sands . . . . . . . . . . . . . . 42.4 Angle Incline 21 15 20 23 17 18 20 18 17 20 20 30 12-15 25 17 20 20 15 20 17 20 15 21 20 18 13-15 18 % Grade 38.3 26.8 36.4 42.4 30.6 32.5 36.4 32.5 30.6 36.4 36.4 57.7 21.2-26.8 46.6 30.6 36.4 36.4 26.8 36.4 30.6 36.4 26.8 38.3 36.4 32.5 23.1-26.8 32.5
NOTE: *When mass slips due to water lubrication rib type belts permit three to five degrees increase.
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b. Material characteristics can affect other elements of conveyor selection. Heavier material or large lumps may require more HP, heavier belt, closer idler spacing and impact idlers at feed points. Abrasiveness may require wear liners or special rubber compositions. Moisture may require steeper hopper sides, wider belts, anti-buildup return idlers and special belt wipers. Dust content may require special discharge hoods and chutes, slower belt speeds and hood covers. Sharp material may require impact idlers, wear liners, special belt and plate feeder. Lightweight materials may require wider belts and less horsepower. c. Conveyor Belt Conveyor belt consists of three elements: top cover, carcass and bottom cover. The belt carcass carries the tension forces necessary in starting and moving the loaded belt, absorbs the impact energy of material loading, and provides the necessary stability for proper alignment and load support over idlers under all operating conditions. Because the primary function of the cover is to protect the carcass, it must resist the wearing effects of abrasion and gouging, which vary according to the type of material conveyed. The top cover will generally be thicker than the bottom cover because the concentration of wear is usually on the top, or carrying side. The belt is rated in terms of maximum recommended operating tension pounds per inch of width (PIW). The PIW of the fabric used in the belt is multiplied by the number of plies in the construction of the belt to determine the total PIW rating of the belt.
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d. Idlers Idler selection is based on the type of service, operating condition, load carried and belt speed. CEMA IDLER CLASSIFICATION
Classification Former Series No. Roll Diameter (Inches) Description
A4 A5 B4 B5 C4 C5 C6 D5 D6 D7 E6
I I II II III III IV NA NA VI V
4 5 4 5 4 5 6 5 6 7 6
Light Duty Light Duty Light Duty Light Duty Medium Duty Medium Duty Medium Duty Medium Duty Medium Duty Heavy Duty Heavy Duty
2. Length Length is determined one of three ways: a. Lift Height Required: When lift height is the determining factor, as a rule of thumb an 18 degree incline is used, where 3 x height needed appriximates the conveyor length required. Particle size, moisture and other factors affect the maximum incline angle. If the material tends to have a conveyable angle that is less than 18 degrees, a longer conveyor needs to be selected to achieve the desired lift height. b. Distance to be conveyed c. Stockpile Capacity Desired
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OR VEY N CO
80' 40' 50' 60'
' 120
' 100
12 9
40' 171
50'
60'
80'
100'
120'
150'
ELEVATION IN FEET
IN GTH N E L
T FEE
' 150
18 15
60'
C L Head Pulley
2' H=Sin(L)+2'
CONVEYOR ELEVATION
Conveyor Length 40 40 40 40 60 60 60 60 80 80 80 80 100 100 100 100 120 120 120 120 150 150 150 150 Conveyor Angle 12 15 18 21 12 15 18 21 12 15 18 21 12 15 18 21 12 15 18 21 12 15 18 21 Height (ft.) 10.3 12.4 14.4 16.3 14.5 17.5 20.5 23.5 18.6 22.7 26.7 30.7 22.8 27.9 32.9 37.8 26.9 33.1 39.1 45.0 33.2 40.8 48.4 55.8
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6 8 10 12 14 16 18 20 22 24
16 21 26 31 36 42 47 52 57 63
26 28 30 35 40 45 50 55 60
LIVE STORAGE
DEAD STORAGE
Live Capacity is the part of pile that can be removed with one feed chute at the center of pile. Approximately 14 of gross capacity of pile. GROSS VOLUME = 13 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
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H = Height of Stockpile - in feet R = Radius of Arc (C L Pile to C L Pivot) - in feet NOTE: V2 based on 37.5 angle of repose = Angle of Arc - in degrees
V1 2
V1 2
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10 2.1 2.5 2.9 3.4 3.8 4.2 4.6 5.1 5.5 5.9 6.3 6.7 7.2 7.6 8.0 8.4 8.8 9.3 9.7 10.1 10.5 11.0 11.4 11.8 12.2 12.6
15
20
25
30
35
40
45
50
55
6.6 7.6 8.5 9.5 10.4 11.4 12.3 13.3 14.2 15.2 16.1 17.1 18.0 19.0 19.9 20.9 21.8 22.7 23.7 24.6 25.6 26.5 27.5 28.4
16.8 18.5 20.2 21.9 23.6 25.3 27.0 28.6 30.3 32.0 33.7 35.4 37.1 38.8 40.4 42.1 43.8 45.5 47.2 48.9 50.5
31.6 34.2 36.9 39.5 42.1 44.8 47.4 50.0 52.7 55.3 57.9 60.6 63.2 65.8 68.4 71.1 73.7 76.3 79.0
56.9 60.7 64.4 68.2 72.0 75.8 79.6 83.4 87.2 91.0 94.8 98.6 102.4 106.1 109.9 113.7
87.7 92.9 98.0 103.2 108.4 113.5 118.7 123.8 129.0 134.2 139.3 144.5 149.6 154.8
134.8 141.5 148.3 155.0 161.8 168.5 175.2 182.0 188.7 195.5 202.2
Examples:
L H R V1 V1 V2 V2 V3 V3 90 90 stockpile stockpile Cu. Yds. Tons 2,385 3,223 5,358 7,237 10,140 13,688 17,150 23,154 32,777 44,247
Tons Cu. Yds. 766 20.2 1,693 45.6 3,167 86.6 5,316 146.8 10,083 281.2
3. TPH Feed See belt carrying capacity chart. As a rule of thumb, at 350 fpm, 35 degree troughing idlers and 100 lbs/cu. ft. material, a 24" belt carries 300 TPH, a 30" belt carries 600 TPH and a 36" belt carries 900 TPH.
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176
NOTE: *Capacity is based on material weighing 100 lb./cu. ft. with 37.5 degree angle of repose, 3-roll, 35 degree idlers and no skirt boards. *Capacity is theoretical based on a full cross section. To use for conveyor sizing, use 75%-80% of the capacity listed above.
4. Conveyor Width There are a number of factors that affect width. These include TPH feed, future considerations, lump size and the % of fines, cross section of how the material settles on the belt and material weight. a. Normally portable conveyors are set-up to run at 350 feet per minute, as this is accepted as the best speed for the greatest number of types of material and optimum component life. When it is desirable to run at a different speed, this will usually be a factory decision based on the material and the capabilities requested by the customer. These variations are generally applicable on engineered systems.
Coal, damp clay, soft ores, overburden and earth, fine-crushed stone
Heavy, hard, sharp-edged ore, coarse-crushed stone Foundry sand, prepared or damp; shakeout sand with small cores, with or without small castings (not hot enought to harm belting) Prepared foundry sand and similar damp (or dry abrasive) materials discharged from belt by rubber-edged plows Nonabrasive Materials discharged from belt by means of plows
200 200 except for wood pulp, where 300 to 400 is preferable 50 to 100
Feeder belts, flat or troughed, for feeding fine, nonabrasive, or midly abrasive materials from hoppers and bins
Any width
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b. Lump size and the % of fines can have a major affect on width selection. As a rule of thumb, the following should be utilized. Width 18" 24" 30" 36" 42" All Lumps 2" Max. 212" 3" 312" 4" 90% Fines 3" 4" 5" 6" 7"
Belts must be wide enough so any combination of lumps and fine material do not load the lumps too close to the edge of the belt. c. The cross section of how the material settles on a moving belt can have a major affect on expected tonnage for a given width conveyor.
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0-19 Angle of repose Uniform size, very small rounded particle, either very wet or very dry, such as dry silica sand, cement, wet concrete, etc.
20-29 Angle of repose Rounded, dry polished particles, of medium weight, such as whole grain or beans.
30-34 Angle of repose Irregular, granular or lumpy materials of medium weight, such as anthracite coal, cottonseed meal, clay, etc.
35-39 Angle of repose Typical common materials such as bituminous coal, stone, most ores, etc.
40-up Angle of repose Irregular, stringy, fibrous, interlocking mateial, such as wood chips, bagasse, tempered foundry sand, etc.
MATERIAL CHARACTERISTICS
d. The material weight affects the volume, which affects the width. Most aggregate weighs between 90110 lbs. per cubic foot. When the weight varies significantly, it can have a dramatic effect on expected belt width needed to achieve a given tonnage. 5. HP Requirements The power required to operate a belt conveyor depends on the maximum tonnage handled, the length of the conveyor, the width of the conveyor and the vertical distance that the material is lifted. Factors X + Y + Z (from tables below) = Total HP Required at Headshaft. The figures shown are based on average conditions with a uniform feed and at a normal operating speed. Additional factors such as pulley friction, skirtboard friction, material acceleration and auxiliary device frictions (mechanical feeder, tripper, etc.) may require an increase in horsepower. Drive efficiency is taken into consideration to determine the motor horsepower required. This can be an additional 10-15% above the headshaft HP. The ability to start a loaded conveyor will also require an additional HP consideration.
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180
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Kolberg Pioneer Inc. manufactures a variety of portable and stationary conveyors designed to meet the customers requirements. As a rule of thumb, Kolberg conveyors are designed with a Class I Drive, 220 PIW 2-ply belt, 5" CEMA B idlers and a belt speed of 350 fpm. At 350 fpm belt speed, basic capacities are: 24" belt width up to 300 TPH; 30" belt width up to 600 TPH; 36" belt width up to 900 TPH. CONVEYOR OPTIONS include: belt cleaners; vertical gravity take-up; horizontal gravity take-up; snub pulley; return belt covers; full hood top belt covers; impact idlers; self-training troughing idlers; self-training return idlers; 220 PIW 2-ply belting with 316" top covers and 1 16" bottom covers; 330 PIW 3-ply belting with 316" top covers and 116" bottom covers; CEMA C idlers; walkway 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. Used primarily as radial stacking conveyors with Kolberg portable screening plants. Come equipped with hydraulic drives to be powered from an auxiliary source. MODEL 2-2440 2-2450 2-3050
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Series 11: Portable, standard duty, lattice frame utility conveyors. Used as transfer conveyors or radial stacking conveyors. MODEL 11-2440 11-2450 11-2460 11-2470 11-3040 11-3050 11-3060 11-3070 SIZE 24" x 40' 24" x 50' 24" x 60' 24" x 70' 30" x 40' 30" x 50' 30" x 60' 30" x 70' MOTOR 7.5 HP 10 HP 10 HP 10 HP 10 HP 15 HP 15 HP 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 Other widths available upon request.
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Series 12: Portable, standard duty, lattice frame feed conveyors and surge bins. Series 11: 30" or 36" wide conveyor incorporating various hopper/feeder combinations. Gravity feed hoppers are used primarily in free flowing materials and are installed directly over the conveyor tail end and are used with top loading equipment. Feeder hoppers generally provide a more accurate metering of material than does a gravity hopper. Belt feeder/hopper belt feeders are commonly used and recommended for handling sand and gravel and sticky materials, such as clay or topsoil that tend to build-up in other types of feeders. A hopper is mounted above the feeder for use with top loading equipment. Reciprocating plate feeder/hoppers reciprocating plate feeders are used in a free-flowing sand and gravel to minimize impact directly to the conveyor belt. A hopper is mounted above the feeder for use with top loading equipment. Gravity feed dozer trap is used primarily in free flowing materials when push loading material with a dozer. Material feeds directly to conveyor belt. Belt feeder/dozer trap includes belt feeder as described above with feed coming from a dozer pushing material into the dozer trap. Plate feeder/dozer trap includes plate feeder as described above with feeder coming from a dozer pushing material into the dozer trap.
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Series 13: Portable, standard duty, lattice frame conveyors. Most often used as radial stacking conveyors. Top folding option for road portability. MODEL 13-2480 13-24100 13-24125 13-3080 13-30100 13-30125 13-3680 13-36100 13-36125 SIZE 24" x 80' 24" x 100' 24" x 125' 30" x 80' 30" x 100' 30" x 125' 36" x 80' 36" x 100' 36" x 125' MOTOR 10 HP 15 HP 15 HP 20 HP 25 HP 25 HP 25 HP 30 HP 40 HP
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Series 31: Portable, heavy duty, lattice frame radial stacking conveyors. Side-folding for road portability. Cam-arm style undercarriage for constant radial travel radius. MODEL 31-2480 31-24100 31-24125 31-3080 31-30100 31-30125 31-3680 31-36100 31-36125 SIZE 24" x 80' 24" x 100' 24" x 125' 30" x 80' 30" x 100' 30" x 125' 36" x 80' 36" x 100' 36" x 125' MOTOR 10 HP 15 HP 15 HP 20 HP 25 HP 25 HP 25 HP 30 HP 40 HP
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Series 33: Portable, heavy duty, telescoping radial stacking conveyors. Because of the stackers ability to move in three directions: raise/lower, radial and extend/retract, it is effective in reducing segregation and degradation of material stockpiles. Unique axle arrangement allows for quick set-up of stacker. Road travel suspension of (8) eight 11:00-22.5 tires on tandem walking beam axle. Gull wing radial stockpiling axle assembly of (4) four 15:00-22.5 tires. Gull wing is hydraulically actuated to lift travel tires off the ground for radial stockpiling. (2) Two horsepower planetary power travel drives are included. Automated stockpiling with PLC controls is available on all models. CONVEYOR LENGTH RETRACTED/ EXTENDED 60'/110' 70'/130' 80'/150' 70'/130' 80'/150' MOTOR MAIN CONV./ EXT. CONV. 15 HP/15 HP 20 HP/20 HP 20 HP/20 HP 30 HP/25 HP 30 HP/30 HP
SIZE 30" x 110' 30" x 130' 30" x 150' 36" x 130' 36" x 150'
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AREA #3
CONVENTIONAL STOCKPILE NON-SEGREGATED STOCKPILE FULL CAPACITY AREA #1 AREA #2 AREA #3
AREA #2
AREA #1
100% 63% 137%
Series 35: In pit, heavy duty, fixed height radial stackers. MODEL 35-24150 35-30150 35-36150 SIZE 24" x 150' 30" x 150' 36" x 150' MOTOR 25 HP 40 HP 60 HP
Series 36: In pit, heavy duty, adjustable height, mast type cable suspended radial stackers. MODEL 36-24100 36-24125 36-24150 36-30100 36-30125 36-30150 36-36100 36-36125 36-36150 SIZE 24" x 100' 24" x 125' 24" x 150' 30" x 100' 30" x 125' 30" x 150' 36" x 100' 36" x 125' 36" x 150' MOTOR 20 HP 20 HP 25 HP 30 HP 30 HP 40 HP 50 HP 50 HP 60 HP
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Series 40: Interplant feed and transfer conveyors, stationary conveyors and specialty conveyors. Includes overland systems thousands of feet long to bring material from the mining area to the processing plant. Standard belt widths are 24", 30" and 36". Other belt widths are available. Lengths are built to specification. Standard frames are 8" channel, 24", 30", 36" and 42" deep angle iron lattice trusses.
190
NOTES:
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PUGMILLS
INTRODUCTION:
Pugmills are used to blend together one or more dry ingredients and/or liquid ingredients into a homogeneous mixture. They were originally developed to mix an aggregate with a liquid bituminous material for a cold mix asphalt. Today they are used for a number of applications including: cold mix asphalt; cement treated based; soil remediation; etc. The Kolberg design is a continuous mix pugmill. It includes two shafts with paddles on each shaft. The shafts are driven by one drive with a set of timing gears between the shafts. The paddles, arranged in a spiral pattern overlap, enhance the quality of the mix. Max. feed size to the pugmill is 2". The max. clearance between the paddle and the wall is 2". This can be adjusted to a min. of 3/4". The paddles can also be rotated to increase wear life, as well as increase retention time in the chamber. The pugmill also comes standard with replaceable wear liners, drop-out bottom for ease of clean-out and a dam gate. The pugmill is available in three sizes: Model 50-486 50-488 50-4810 Size 48" x 6' 48" x 8' 48" x 10' Motor 60 HP 75 HP 100 HP Number of Paddles 40 48 64
The most convenient way to utilize a pugmill is on a portable chassis. Kolberg offers three (3) different configurations of portable plants.
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(Model 52S shown) Model 52 This plant features a 9 cu.yd. hopper with 36" belt feeder, 30" incline feed conveyor and 4' x 6' pugmill located at the end of the plant. It is all electric with an optional on-board genset. It comes on a portable chassis with standard travel features fifth wheel hitch, brakes, lights and mudflaps. A second 6 cu.yd. hopper is available as an option. Model 52S This plant is similar to the Model 52, but larger with more pugmill HP and higher capacity. It includes a 13 cu.yd. primary hopper with 36" belt feeder, 11 cu.yd. secondary hopper with 36" belt feeder, 36" wide incline feed conveyor and a 4' x 8' pugmill located at the end of the plant. This plant is all electric and comes on a portable chassis. Genset optional. Model 53 This plant is highly portable with an 8'6" wide travel width. It includes a 5 cu.yd. gravity hopper, 30" wide incline feed conveyor, 4' x 6' pugmill and a 30" x 25' discharge conveyor. This plant is all electric with an optional on-board genset.
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Astec companies
&
In some cases, data contained in the following section is derived from other sources. To the best of Kolberg-Pioneer and JCIs knowledge, the information shown is correct.
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RAILROAD BALLAST
Ballast is a relatively coarse aggregate which provides a stable load carrying base for trackage as well as quick drainage. Ballast normally would be crushed quarry or slag materials: free of clay, silt, etc. Two typical specifications follow to provide some idea as to general gradations:
Sieve Opening 3" (76.2 mm) 2 2" (63.5 mm) 2" (50.8 mm) 112" (38.1 mm) 1" (25.4 mm)
3 1 1
25 - 60
35 - 70 0 - 15
0 - 13 0- 5 0- 5
NOTE: The above are typical. However, there are many other ballast sizes dependent on job specifications. Note also that ballast is most usually purchased on a unit volume rather than tonnage basis.
Quantities of Cement, Fine Aggregate and Coarse Aggregate Required for One Cubic Yard of Compact Mortar or Concrete
Mixtures Approx. Quantities of Materials Fine Aggregate Cu. Ft. 23.2 25.6 27.5 28.8 11.4 16.6 14.0 12.0 14.7 14.0 12.5 13.8 Cu. Yd. 0.86 0.95 1.02 1.07 0.42 0.61 0.52 0.44 0.54 0.52 0.46 0.51 22.8 16.6 21.0 24.0 20.6 22.4 25.0 23.0 0.85 0.61 0.78 0.89 0.76 0.83 0.92 0.85 Coarse Aggregate Cu. Ft. Cu. Yd.
Cement 1 1 1 1 1 1 1 1 1 1 1 1
C.A. F.A. (Gravel Cement (Sand) or Stone) in Sacks 1.5 2.0 2.5 3.0 1.5 2.0 2.0 2.0 2.5 2.5 2.5 3.0 3 2 3 4 3.5 4 5 5 15.5 12.8 11.0 9.6 7.6 8.3 7.0 6.0 5.9 5.6 5.0 4.6
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RIPRAP
Riprap as used for facing dams, canals and waterways is normally a coarse, graded material. Typical general specifications would call for a minimum 160 lb./ft.3 stone, free of cracks and seams with no sand, clay, dirt, etc. A typical specification will probably give the percent passing by particle weight such as:
Percent Passing 100 50 - 70 30 - 50 0 - 15 15" Blanket 165 lbs. 50 lbs. 35 lbs. 10 lbs. 24" Blanket 670 lbs. 200 lbs. 135 lbs. 40 lbs.
In order to relate the above weights to rock size, refer to the following size/density chart:
Weights of RiprapPounds
Cubical Size (in.) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 24 25 28 30 32 34 36 39
NOTE: The above is given as general information only; each job will carry its individual specification.
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HP.
2 3 4
7 9.4 11 15.2 20 28 46
25 30 35 45 60 90 150
197
HP.
M.C.M. In order to avoid excessive voltage drop where long runs are involved, it may be necessary to use conductors and conduit of sizes larger than the minimum sizes listed above. ** Branch-circuit fuses must be large enough to carry the starting current, hence they protect against short-circuit only. Additional protection of an approved type must be provided to protect each motor against normal operating overloads. * For full-voltage starting of normal torque, normal starting current motor. For reduced-voltage starting of normal torque, normal starting current motor, and for full-voltage starting of high-reactance, low starting current squirrel-cage motors.
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V 212 212 234 318 234 318 334 312 334 312 438 458 438 458 5 538 5 538 558 618 558 618 7 678 7 678 838 838
Keyway
614 614 7 7 7 7 8 8 8 8 9 9 9 9 10 10 10 10 11 11
5 4 514 6 6 558 5 8
5
2 8
1
6 8
1
2 8
3
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CURRENT CARRYING CAPACITIES AND CABLE DIAMETER SIZES FOR THE PORTABLE CABLES
Type SO Cord
AWG Size 250 MCM 4/0 3/0 2/0 1/0 1 2 3 4 6 8 10 12 14 16 18 Amp Capacity Diameter (Inches) 2 Cond. 3 Cond. 4 Cond.
200
3 Conductor Type G
Amp Capacity 275 245 220 190 160 145 130 110 95 75 55 Diameter (Inches) 2.39 2.04 1.89 1.75 1.65 1.51 1.34 1.24 1.17 1.01 0.91
4 Conductor Type W
Amp* Capacity 210 190 170 145 125 110 95 85 60 50 Diameter (Inches) 2.26 2.07 1.93 1.79 1.68 1.48 1.34 1.27 1.10 0.99
25 20 15 10 7
Above Data from Western Insulated Wire Co. fro Bronco 66 Certified Cable
*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.
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DREDGE PUMP
SIZE 4 6 8 10 12 14 16 18 20 SLURRY GPM 680 1,500 2,700 4,100 5,900 7,300 9,670 12,280 15,270 20% Solids @ 100 lb./cu. ft. (% Solids by Weight) NOTE: GPM 17.6 = TPH TPH X 17.6 = GPM Above information can be used as a guide in preliminary selection of material handling components. For plants charged by dredge pumps. Proper selection of sand processing components is in part controlled by maximum amount of water in the slurry. Prior to final selection of machinery, complete information must be assimilated so sound judgement can be exercised. TPH 38 85 153 233 335 414 550 696 866
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5"
200 150
2-1/2"
200 150
2"
100 90 80 70 60 50 40 30 25 20 3 4 5 6 7
1-1/2" 1-1/4"
100 90 80 70 60 50
40 30 25 20
NOTE: Based on following IDs for Std. Wt. W:I or Steel Pipe
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.2
FRICTION LOSS FOR WATER IN FEET OF HEAD PER 100 FT. PIPE .3 .4 .5 .6 .8 1.0 2 3 4 5 6 8 10 20
30
40 50 5000 4000 3000 2000 1000 1000 800 700 600 500 400
8"
6" 5"
80 70 60 50 40 30 20
10 .1 .2 .3 .4 .5 .6 .8 1.0 2 3 4 5 6 8 10 20 FRICTION LOSS FOR WATER IN FEET OF HEAD PER 100 FT. PIPE 30 40 50
10
204
25
50
300
0 400
GENERAL Measure overflow depth (h) at a distance back of weir at least four times h. Use a flat strip taped to the end of a carpenters level. Multiply figure from curve by length of weir. FLUME OR LAUNDER Use a bevel-edge steel plate or board with sharp edge upstream. L(Weir length) and D (depth of water behind weir) must each be at least three times h. Water or slurry must fall free of weir; i.e., with air space underneath. If possible, drill air holes in side of launder on downstream side of weir plate. Curve does not apply to triangular or notched weirs.
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206
40
60
80
100
600
700
800
1000
WFM WFM WFM WFM WFM WFM WFM WFM WFM WFM WFM
.034 .052 .055 .057 .060 .062 .064 .067 .072 .074 .076 .080
.20 .40 .45 .50 .55 .60 .65 .70 .80 .85 .90 1.0
.24 .49 .55 .61 .67 .73 .80 .86 .98 1.1 1.1 1.2
.39 .77 .87 .97 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.9
.45 .89 1.0 1.1 1.2 1.3 1.5 1.6 1.8 1.9 2.0 2.2
.55 1.1 1.2 1.4 1.5 1.6 1.8 1.9 2.2 2.3 2.5 2.7
.63 1.3 1.4 1.6 1.7 1.9 2.1 2.2 2.5 2.7 2.8 3.2
.71 1.4 1.5 1.8 1.9 2.1 2.3 2.5 2.8 3.0 3.2 3.5
.77 1.6 1.7 1.9 2.1 2.3 2.5 2.7 3.1 3.3 3.5 3.9
.84 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.4 3.6 3.8 4.2
.89 1.8 2.0 2.2 2.5 2.7 2.9 3.1 3.6 3.8 4.0 4.5
1.0 2.0 2.2 2.5 2.8 3.0 3.3 3.5 4.0 4.2 4.5 5.0
.92 1.0 .99 1.1 1.1 1.2 1.3 1.4 1.3 1.3 1.4 1.6
WFM 10
207
208
NOZZLE Equiv. NUMBER Orif. Male No. Dia.
1
10
15
20
30
200
300
400
500
WFM* 70 WFM 100 WFM 150 WFM 200 WFM 250 WFM 300 WFM 400
32 7 64 9 64 5 32 11 64 3 16 13 64 7 32 1 4 19 64 11 32 25 64 27 64 1 2
.75 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5.0 7.5 10.0 12.5 15.0 20.2
.92 1.2 1.8 2.5 3.1 3.7 4.3 5.0 6.1 9.2 12.2 15.7 18.4 24.4
1.1 1.4 2.1 2.8 3.5 4.2 4.9 5.6 7.1 10.6 14.1 17.7 21.2 28.2
1.3 1.7 2.6 3.5 4.3 5.2 6.1 5.8 8.6 13.0 17.3 21.6 26.0 34.6
1.5 2.0 3.0 4.0 5.0 6.0 7.0 8.0 10.0 15.0 20.0 25.0 30.0 40.0
1.8 2.5 3.7 4.9 6.1 7.3 8.6 9.8 12.2 18.4 24.5 30.5 36.8 49.0
2.1 2.8 4.2 5.7 7.1 8.5 9.9 11.4 14.1 21.2 28.3 35.4 42.4 56.6
2.4 3.2 4.7 6.3 7.9 9.5 11.1 12.6 15.8 23.7 31.6 39.4 47.4 63.2
4.1 5.5 8.2 11.0 13.7 16.4 19.2 21.9 27.4 41.1 54.7 68.4 82.1
4.7 6.3 9.5 12.7 15.8 19.0 22.2 25.3 31.6 47.4 63.3 79.0
5.3 7.1 10.6 14.2 17.7 21.2 24.8 28.3 35.3 53.1 70.8 88.4
9.7 11.2 11.6 13.4 13.5 15.7 15.4 17.9 19.4 22.3 29.0 33.5 38.7 44.3 48.4 55.8 58.0 66.9
94.8 106.0
A
11 31
B
7 9
C
5
8 4 8 2 4
16 32
16 16 16 8 16
16 8 2 8 16
3 7
1 11764 12764
11
7 11
1 5
1 mile
{
{
1 furlough 1 station
= =
8 furlongs 80 chains 320 rods 1760 yards 5280 feet 10 chains 220 yards 6.06 rods 33.3 yards 100 feet
1 chain
{
{ {
= = =
4 rods 22 yards 66 feet 100 links 5.5 yards 16.5 feet 3 feet 36 inches 12 inches
Land Measure
1 township 1 sq. mile 1 acre = = =
{ {
36 sections 36 sq. miles 1 section 640 acres 4,840 sq. yards 43,560 sq. feet 160 sq. rods
= = =
272 sq. feet { 30 sq. yards 1,296 sq. inches { 9 sq. feet
1 4 1 4
Cubic Measure
1 cubic yard = 1 cord (wood) = 1 ton (shipping) = 27 cubic feet 4x4x8 ft. = 128 cu. ft. 40 cubic ft. 1 cu. ft. = 1 bushel = 1 gallon = 1728 cu. in. 2150.42 cu. in. 231 cu. in.
Weights (Commercial)
1 long ton = 2250 lbs. 1 short ton = 2000 lbs. 1 pound = 16 ounces 1 ounce = 16 drams
1 pennyweight = 24 grains
Liquid Measure
1 pint (pt.) 1 quart (qt.) = = = =
{ {
1 gallon (gal.) =
4 gills (gl.) 28.875 cu. in. 2 pints 57.75 cu. in. 4 quarts 8 pints 32 gills 231 cu. in. 812 lbs. @ 62F
= = =
63 gallons 311/2 gallons 7.48 U.S. gals. 1728 cu. in. 6212 lbs. @ 62F
210
{
= = =
Mariners Measure
1 fathom 1 cable length 1 nautical mile 6 feet 120 fathoms 6,080 feet 1 marine league = 1 statute mile 3 marine miles
1 2
Measures of Power
1 BTU per minute =
{
{
1 horsepower
1 watt
1 kilowatt
{ { {
.0236 17.6 .0176 778 .0226 .001285 746 .746 33,000 42.4 .00134 .001 44.2 .0568 1.341 1000 44.250 56.8
horsepower watts kilowatts foot lbs. per min. watts BTU per min. watts kilowatts ft. lbs. per min. BTU per min. horsepower kilowatts ft. lbs. per min. BTU per min. horsepower watts ft. lbs. per min. BTU per min.
100 m2
2
Linear Measure
1 centimeter (cm)=
{ = { { = {
= = =
Weight
1 centigram (cg) = 10 milligrams (mg) 100 mg 10 cg 1,000 mg 10 dg. 1 hectogram (hg) 1 dekagram (dkg) 1 kilogram (kg) 1 metric ton (1) = = = =
{ 100g 10 dkg
10 g g { 1,000 10 hg 1,000 kg
211
1,000 cubic millimeters (mm3) 1,000,000 mm3 1,000 cm3 1 stere 1,000,000,000 mm3 1,000,000 cm3 1,000 dm3
Volume Measure
1 centiliter (cl) 1 deciliter (dl) 1 liter* (l) = =
{ = {
{ = {
*The liter is defined as the volume occupied, under standard conditions, by a quantity of pure water having a mass of 1 kilogram.
Power
1 metric horsepower =
Flow
Cu. ft. per min. x 0.028314 = cu. m per min. Cu. m per min. x 35.3182 = cu. ft. per min.
Length
Centimeters Meters Meters Kilometers Kilometers x 0.3937 x 3.2808 x 1.0936 x 0.6214 x 0.53959 *Statute miles = inches = feet = yards = miles* = miles** Inches Feet Yards Miles* Miles** x 2.5400 = centimeters x 0.3048 = meters x 0.9144 = meters x 1.6093 = kilometers x 1.85325 = kilometers **Nautical miles
Power
Metric horsepower x .98632 = U.S. horsepower U.S. horsepower x 1.01387 = metric horsepower
Pressure
Kgs per sq. cm Lbs. per sq. in. Kgs per sq. in. Kgs per sq. m Lbs. per sq. ft. Kgs per sq. m x 14.223 x 0.0703 x 0.2048 x .204817 x 4.8824 x .00009144 = lbs. per sq. in. = kgs per sq. cm = lbs. per sq. ft. = lbs. per sq. ft. = kgs per sq. m = tons (long) per sq. ft.
212
Weight
Grams Grams Grams Kgs Kgs Kgs Tons* Tons* Cu. cm. Cu. m Cu. m Liters Liters Liters Liters x 15.4324 x 0.0353 x 0.0022 x 2.2046 x 0.0011 x 0.00098 x 1.1023 x 2204.62 x 0.0610 x 35.3145 x 1.3079 x 61.0250 x 0.0353 x 0.2642 x 0.0284 = grains = oz. = lbs. = lbs. = tons (short) = tons (long) = ton (short) = lbs. = cu. in. = cu. ft. = cu. yds. = cu. in. = cu. ft. = gals. (U.S.) = bushels (U.S.) Grains Oz. Lbs. Lbs. Lbs. Tons (short) Tons (short) Tons (long) x 0.0648 x 28.3495 x 453.592 x 0.4536 x 0.0004536 x 907.1848 x 0.9072 x 1016.05 x 16.3872 x 0.0283 x 0.7646 x 0.0164 x 27.3162 x 3.7853 x 35.2383 =g =g =g = kg = tons* = kg = tons* = kg = cu. cm = cu. m = cu. m = liters = liters = liters = liters
Volume
Cu. ins. Cu. ft. Cu. yds. Cu. ins. Cu. ft. Gallons Bushels
Liters x
1000.027 = cu. cm 1.0567 = qt. (liquid) or 0.9081 = qt. (dry) 2.2046 = lb. of pure water at 4C = 1 kg.
213
214
NOTE: The above weights may vary in accordance with moisture content, texture; etc. MISCELLANEOUS USEFUL INFORMATION Area of circle: Multiply square of diameter by .7854. Area of rectangle: Multiply length by breadth. Area of triangle: Multiply base by 12 perpendicular height. Area of ellipse: Multiply product of both diameters by .7854. Area of sector of circle: Multiply arc by 12 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 13 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 12 height. Diameter of circle: Multiply circumference by .31831.
215
APPROXIMATE WEIGHTS IN POUNDS PER CUBIC YARD OF COMMON MINERAL AGGREGATES WITH VARIOUS PERCENTAGES OF VOIDS (SPECIFIC GRAVITY OF 1 = APPROX. 1685 LBS.) Specific Gravity 2.8 2.9 3.0 3.1 2.6 2.7 2.8 2.4 2.5 2.6 2.7 2.0 2.1 2.2 2.3 2.4 2.5 1.5 2.65 Percentage of Voids 25% 3540 3660 3790 3910 3280 3410 3540 3030 3160 3280 3410 2530 2650 2780 2900 3030 3160 1890 3350 30% 3300 3420 3540 3650 35% 3070 3180 3290 3390 40% 2830 2930 3030 3130 45% 2600 2690 2780 2870 50% 2360 2440 2530 2610 2190 2270 2360 2020 2100 2190 2270 1680 1770 1850 1940 2020 2100 1260 2230
3060 2850 3180 2960 3300 3070 2830 2950 3060 3180 2360 2470 2590 2710 2830 2950 2630 2740 2850 2960 2190 2300 2410 2520 2630 2740
2630 2410 2730 2500 2830 2600 2420 2520 2630 2730 2020 2120 2220 2320 2420 2520 2020 2310 2410 2500 1850 1950 2040 2120 2220 2310
Sandstone
Slag
Most limestone, gravel and sand will absorb one percent or more water by weight. Free water in moist sand approximates two percent, moderately wet 4 percent, and very wet seven percent.
DUMPING ANGLES
Angles at which different materials will slide on steel Ashes, Dry . . . . . . . . . . . 33 Ashes, Moist . . . . . . . . . 38 Ashes, Wet. . . . . . . . . . . 30 Asphalt. . . . . . . . . . . . . . 45 Cinders, Dry. . . . . . . . . . 33 Cinders, Moist . . . . . . . . 34 Cinders, Wet . . . . . . . . . 31 Cinders & Clay . . . . . . . . 30 Clay . . . . . . . . . . . . . . . . 45 Coal, Hard . . . . . . . . . . . 24 Coal, Soft . . . . . . . . . . . . 30 Coke. . . . . . . . . . . . . . . . 23 Concrete . . . . . . . . . . . . 30 Earth, Loose. . . . . . . . . . 28 Earth, Compact . . . . . . . 50 Garbage . . . . . . . . . . . . . 30 Gravel . . . . . . . . . . . . . . 40 Ore, Dry . . . . . . . . . . . . . 30 Ore, Fresh Mined . . . . . . 37 Rubble . . . . . . . . . . . . . . 45 Sand, Dry. . . . . . . . . . . . 33 Sand, Moist . . . . . . . . . . 40 Sand & Crushed Stone. . 27 Stone . . . . . . . . . . . . . . . 30 Stone, Broken . . . . . . . . 27 Stone, Crushed . . . . . . . 30
216
mm .39687 .79375 1.1906 1.5875 1.9844 2.3812 2.7781 3.1750 3.5719 3.9687 4.3656 4.7625 5.1594 5.5562 5.931 6.3500 6.7469 7.1437 7.5406 7.9375 8.3344 8.7312 9.1281 9.5250 9.9219 10.319 10.716 11.112 11.509 11.906 12.303 12.700 .015625 .03125 .046875 .0625 .078125 .09375 .109375 .125 .140625 .15625 .171875 .1875 .203125 .21875 .234375 .25 .265625 .28125 .296875 .3125 .328125 .34375 .359375 .375 .390626 .40625 .421875 .4375 .453125 .46875 .484375 .5
Inch
33 17
mm 13.097 13.494 13.891 14.287 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.462 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.637 21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.812 24.209 24.606 25.003 .515625 .53125 .546875 .5625 .578125 .59375 .609375 .625 .640625 .65625 .671875 .6875 .703125 .71875 .734375 .75 .765625 .78125 .796875 .8125 .828125 .84375 .859375 .875 .890625 .90625 .921875 .9375 .953125 .96875 .984375 217
64 32 3 64 1 16
5 3
64 32 35 64 9 16
37 19
64 32 7 64 1 8 64 32 11 64 3 16
5 13 7 9
64 32 39 64 5 8
41 21
64 32 43 64 11 16
45 23
64 32 15 64 1 4
17 9
64 32 47 64 3 4
49 25
64 32 19 64 5 16
21 11
64 32 51 64 13 16
53 27
64 32 23 64 3 8
25 13
64 32 55 64 7 8 64 32 59 64 15 16
29 61 31 57
64 32 27 64 7 16
29 15
64 32 31 64 1 2
64 32 63 64
Dia. 10 1012 11 1112 12 1212 13 1312 14 1412 14 1512 16 1612 17 1712 18 1812 19 1912 20 2012 21 2112 22 2212 23 2312 24 2412 25 26 27 28 29
Area 78.54 86.59 95.03 103.86 113.09 122.71 132.73 143.13 153.93 165.13 176.71 188.69 201.06 213.82 226.98 240.52 254.46 268.80 283.52 298.64 314.16 330.06 346.36 363.05 380.13 397.60 415.47 433.73 452.39 471.43 490.87 530.93 572.55 615.75 660.52
Cir. 31.41 32.98 34.55 36.12 37.69 39.27 40.84 42.41 43.98 45.55 47.12 48.69 50.26 51.83 53.40 54.97 56.46 58.11 59.69 61.26 62.83 64.40 65.97 67.54 69.11 70.68 72.25 73.82 75.39 76.96 78.54 81.68 84.82 87.96 91.10
Dia. 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
Area
Cir.
Dia. 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
Area 3318.3 3421.2 3525.6 3631.6 3739.2 3848.4 3959.2 4071.5 4185.3 4300.8 4417.8 4536.4 4656.0 4778.3 4901.6 5026.5 5153.0 5281.0 5410.6 5541.7 5674.5 5808.8 5944.6 6082.1 6221.1 6361.7 6503.8 6647.6 6792.9 6939.7 7088.2 7238.2 7389.8 7542.9 7697.7
Cir. 204.2 207.3 210.4 213.6 216.7 219.9 223.0 226.1 229.3 232.4 235.6 238.7 241.9 245.0 248.1 251.3 254.4 257.6 260.7 263.8 257.0 270.1 272.3 276.4 279.6 282.7 285.8 289.0 292.1 295.3 298.4 301.5 304.7 307.8 311.0
8 4 3 8 1 2 5 8
3 7
706.86 94.24 754.76 97.38 804.24 100.5 855.30 103.6 907.92 106.8 962.11 109.9 1017.8 113.0 1075.2 116.2 1134.1 119.3 1194.5 122.5 1256.6 125.6 1320.2 128.8 1385.4 131.9 1452.2 135.0 1520.5 138.2 1590.4 141.3 1661.9 144.5 1734.9 147.6 1809.5 150.7 1885.7 153.9 1963.5 157.0 2042.8 160.2 2123.7 163.3 2206.1 166.5 2290.2 169.6 2375.8 172.7 2463.0 175.9 2551.7 179.0 2642.0 182.2 2733.9 185.3 2827.4 188.4 2922.4 191.6 3019.0 194.7 3117.2 197.9 3216.9 201.0
0.1104 1.178 0.1963 1.570 0.3067 1.963 0.4417 2.356 0.6013 2.748 0.7854 3.141 0.9940 3.534 1.227 1.484 1.767 2.073 2.405 2.761 3.141 3.976 4.908 5.939 7.068 3.927 4.319 4.712 5.105 5.497 5.890 6.283 7.068 7.854 8.639 9.424
4 8
1 118 114 138 112 158 134 178 2 214 212 234 3 314 312 4
334 11.044 11.78 412 15.904 14.13 5 6 7 19.635 15.70 28.274 18.84 38.484 21.99
712 44.178 23.56 8 9 50.265 25.13 63.617 28.27 812 56.745 26.70 912 70.882 29.84
218
TRIGONOMETRIC FUNCTIONS
Angle 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Sin 0.000 0.017 0.035 0.052 0.070 0.087 0.105 0.112 0.139 0.156 0.174 0.191 0.208 0.225 0.242 0.259 0.276 0.292 0.309 0.326 0.342 0.358 0.375 0.391 0.407 0.423 0.438 0.454 0.469 0.485 0.500 0.515 0.530 0.545 0.559 0.574 0.588 0.602 0.616 0.629 0.643 0.656 0.669 0.682 0.695 0.707 Cos 1.000 0.999 0.999 0.999 0.998 0.996 0.995 0.993 0.990 0.988 0.985 0.982 0.978 0.974 0.970 0.966 0.961 0.956 0.951 0.946 0.940 0.934 0.927 0.921 0.914 0.906 0.898 0.891 0.883 0.875 0.866 0.857 0.848 0.839 0.829 0.819 0.809 0.799 0.788 0.777 0.766 0.755 0.743 0.731 0.719 0.707 Tan 0.000 0.017 0.035 0.052 0.070 0.087 0.105 0.123 0.141 0.158 0.176 0.194 0.213 0.231 0.249 0.268 0.287 0.306 0.325 0.344 0.364 0.384 0.404 0.424 0.445 0.466 0.488 0.510 0.532 0.554 0.577 0.601 0.625 0.649 0.675 0.700 0.727 0.754 0.781 0.810 0.839 0.869 0.900 0.933 0.966 1.000 Angle 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 Sin 0.719 0.731 0.743 0.755 0.766 0.777 0.788 0.799 0.809 0.819 0.829 0.839 0.848 0.857 0.866 0.875 0.883 0.891 0.898 0.906 0.914 0.921 0.927 0.934 0.940 0.946 0.951 0.956 0.961 0.966 0.970 0.974 0.978 0.982 0.985 0.988 0.990 0.993 0.995 0.996 0.998 0.999 0.999 0.999 1.000 Cos 0.695 0.682 0.699 0.656 0.643 0.629 0.616 0.602 0.588 0.574 0.559 0.545 0.530 0.515 0.500 0.485 0.469 0.454 0.438 0.423 0.407 0.391 0.375 0.358 0.342 0.326 0.309 0.292 0.276 0.259 0.242 0.225 0.208 0.191 0.174 0.156 0.139 0.122 0.105 0.087 0.070 0.035 0.035 0.017 0.000 Tan 1.04 1.07 1.11 1.15 1.19 1.23 1.28 1.33 1.38 1.43 1.48 1.54 1.60 1.66 1.73 1.80 1.88 1.96 2.05 2.14 2.25 2.36 2.48 2.61 2.75 2.90 3.08 3.27 3.49 3.73 4.01 4.33 4.70 5.14 5.67 6.31 7.12 8.14 9.51 11.43 14.30 19.08 28.64 57.28 Infinity
219
Size (Inches)
Size (Inches)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
.2391 .2242 .2092 .1943 .1793 .1644 .1494 .1345 .1196 .1046 .0897 .0747 .0673
11.25 10.625 10.000 9.375 8.750 8.125 7.500 6.875 6.250 5.625 5.000 4.375 3.750 3.125 2.812
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
.0598 .0538 .0478 .0418 .0359 .0329 .0299 .0269 .0239 .0209 .0179 .0164 .0149 .0135 .0120
2.500 2.250 2.000 1.750 1.500 1.375 1.250 1.125 1.000 .875 .750 .6875 .625 .5625 .500
NOTE: (1/4" Thick and Heavier Are Called Plates.) To avoid errors specify decimal part of one inch or mention gauge number and the name of the gauge. Orders for a definite gauge weight or gauge thickness will be subject to standard gauge weight or gauge thickness tolerance, applying equally plus and minus form the ordered gauge weight or gauge thickness. U.S. Standard GaugeIron and steel sheets. Note: U.S. Standard Gauge was established by act of Congress in 1893, in which weights per square foot were indicated by gauge number. The weight, not thickness, is determining factor when the material is ordered to this gauge.
220
Rd. .190 2.04 2.19 2.35 2.51 2.67 3.01 3.38 3.77 4.17 4.60 5.05 5.52 6.01 7.05 8.18 9.39 10.68 12.06 13.52 15.06 16.69 20.20 24.03
Hex. 2.10 2.25 2.42 2.59 2.7 2.95 3.32 3.37 4.15 4.60 5.07 5.57 6.09 6.63 7.78 9.02 10.36 11.78 13.30 14.91 16.61 18.40 22.27 26.50
Sq. 2.42 2.60 2.79 2.99 3.19 3.40 3.84 4.30 4.80 5.31 5.86 6.43 7.03 7.65 8.98 10.41 11.95 13.60 15.35 17.21 19.18 21.25 25.71 30.60
16 32 1 8 5 32 3 16 7 32 1 4 9 32 5 16 11 32 3 8 13 32 7 16 15 32 1 2 17 32 9 16 19 32 5 8 21 32 11 16 23 32 3 4 25 32 13 16
3
32 8 29 32
15
16
31
1 1116 118 1316 114 1516 138 1716 112 158 134 178 2 218 214 238 212 234 3
32
Thickness
16". . . . . . . . . . . . . .2125 118" . . . . . . . . . . . . .4250 3 ". . . . . . . . . . . . . .6375 16 1 " . . . . . . . . . . . . . .8500 4 5 ". . . . . . . . . . . . 1.0600 16 3 " . . . . . . . . . . . . 1.2750 8 7 ". . . . . . . . . . . . 1.4880 16 1 " . . . . . . . . . . . . 1.7000 2 9 ". . . . . . . . . . . . 1.9130 16 5 " . . . . . . . . . . . . 2.1250 8 11 " . . . . . . . . . . . 2.3380 16 3 " . . . . . . . . . . . . 2.5500 4 13 ". . . . . . . . . . . . . . . . . . . . . . . 2.7630 16
1
" . . . . . . . . . . . . . 2.975 134" . . . . . . . . . . . 5.950 16" . . . . . . . . . . . . 3.188 11316" . . . . . . . . . . 6.163 1" . . . . . . . . . . . . . 3.400 178" . . . . . . . . . . . 6.375 11 " . . . . . . . . . . . . 3.613 115 " . . . . . . . . . . 6.588 16 16 118" . . . . . . . . . . . . 3.825 2" . . . . . . . . . . . . . 6.800 13 " . . . . . . . . . . . . 4.038 21 " . . . . . . . . . . . 7.225 16 8 114" . . . . . . . . . . . . 4.250 214" . . . . . . . . . . . 7.650 11516". . . . . . . . . . . 4.463 238" . . . . . . . . . . . 8.075 138" . . . . . . . . . . . . 4.675 212" . . . . . . . . . . . 8.500 1716" . . . . . . . . . . . 4.888 258" . . . . . . . . . . . 8.925 112" . . . . . . . . . . . . 5.100 234" . . . . . . . . . . . 9.350 1916" . . . . . . . . . . . 5.313 278" . . . . . . . . . . . 9.775 158" . . . . . . . . . . . . 5.525 3" . . . . . . . . . . . . 10.200 11116" . . . . . . . . . . . 5.738
221
Ga. No.
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
.259 .238 .220 .203 .180 .165 .148 .134 .120 .109 .095 .083 .072 .065 .058 .049 .042 .035 .032 .028 .025 .022 .020 .018 .016 .014 .013 .012
10.567 9.710 8.976 8.282 7.344 6.732 6.038 5.467 4.896 4.447 3.876 3.386 2.938 2.652 2.366 1.999 1.714 1.428 1.306 1.142 1.020 .898 .816 .734 .653 .571 .530 .490
.2294 .2043 .1819 .1620 .1443 .1285 .1144 .1019 .0907 .0808 .0720 .0641 .0571 .0508 .0453 .0403 .0359 .0320 .0285 .0253 .0226 .0201 .0179 .0159 .0142 .0126 .0113 .0100
.2437 .2253 .2070 .1920 .1770 .1620 .1483 .1350 .1205 .1055 .0915 .0800 .0720 .0625 .0540 .0475 .0410 .0348 .0317 .0286 .0258 .0230 .0204 .0181 .0173 .0162 .0150 .0140
NOTE: Birmingham or Stubs GaugeCold rolled strip, round edge flat wire, cold roll spring steel, seamless steel and stainless tubing and boiler tubes. *B.W. Gauge weights per sq. ft. are theoretical and based on steel weight of 40.8 lbs. per sq. ft. of 1" thickness; weight of hot rolled strip is predicted by using this factor. Steel Wire Gauge(Washburn & Moen Gauge)Round steel wire in black annealed, bright basic, galvanized, tinned and copper coated.
222
Size
9 16 5 8 3 4 7 8
12
4 16 3 8 7 16 1 2
223
SPEED RATIOS
Speed ratios and groups from which speed change selection can be made. Revolutions per minute of faster shaft Ratio of transmission = Revolutions per minute of slower shaft Number of Teeth in Driver Gear & Sprocket 17 19 21 23 25 27 30 1.12 1.00 0.91 0.83 0.76 0.70 0.64 1.23 1.10 1.00 0.91 0.84 0.78 0.70 1.35 1.21 1.10 1.00 0.92 0.85 0.78 1.47 1.32 1.19 1.09 1.00 0.93 0.83 1.59 1.42 1.28 1.17 1.08 1.00 0.90 1.77 1.58 1.43 1.30 1.20 1.11 1.00 1.94 1.74 1.57 1.43 1.32 1.22 1.19 2.12 1.89 1.71 1.56 1.44 1.33 1.20 2.35 2.10 1.90 1.74 1.60 1.48 1.33 2.65 2.37 2.14 1.96 1.80 1.67 1.50 2.94 2.63 2.38 2.18 2.00 1.85 1.67 3.24 2.89 2.62 2.39 2.20 2.04 1.83 3.53 3.16 2.86 2.61 2.40 2.22 2.00 4.00 3.58 3.24 2.96 2.72 2.52 2.27 4.41 3.95 3.57 3.26 3.00 2.78 4.94 4.42 4.00 3.65 3.36 5.30 4.74 4.28 3.91 6.00 5.37 4.86 Number of Teeth in Driver Gear & Sprocket 36 40 45 50 55 60 68 0.53 0.48 0.42 0.38 0.35 0.32 0.28 0.58 0.53 0.47 0.42 0.38 0.35 0.31 0.64 0.58 0.51 0.46 0.42 0.38 0.34 0.70 0.63 0.56 0.50 0.46 0.42 0.37 0.75 0.68 0.60 0.54 0.49 0.45 0.40 0.83 0.75 0.67 0.60 0.55 0.50 0.44 0.92 0.83 0.73 0.66 0.60 0.55 1.00 0.90 0.80 0.72 0.65 1.11 1.00 0.89 0.80 1.25 1.13 1.00 1.30 1.25 1.53
19 21 23 25 27 30 33 36 40 45 50 55 60 68 75 84 90 102
33 0.58 0.65 0.70 0.76 0.82 0.91 1.00 1.09 1.21 1.36 1.52 1.67 1.82
19 21 23 25 27 30 33 36 40 45 50 55
Chain speed, except for high speed RC and silent chains, should not exceed 500 ft. per min. Working load should be held under 16 the ultimate strength for speeds up to 200 f.p.m., 1/10 where speed is between 200 and 300 f.p.m., and less if speed exceeds 300 f.p.m.
224
225
APPROX. SAFE LOAD FOR CHAINS AND WIRE ROPES UNDER DIFFERENT LOADING CONDITIONS
Alloy Sling Chain ASTM A-391 Approx. Working Load Limits Single Leg Alloy Chain Size Inch mm Lbs. kg 1 6.35 3,250 1474 4
3 1
Double Leg
8 2 5 8 3 4 7 8
1 114
9.52 6,600 2994 11,400 5171 9,300 4218 12.7 15.9 19.0 22.2 25.4 31.7
11,250 5103 19,500 8845 15,900 7212 11,250 5103 16,500 7484 28,600 12973 23,300 10559 16,500 7484 23,000 10433 39,800 18053 32,500 14742 23,000 10433 28,750 13041 49,800 22589 40,700 18461 28,750 13041 38,750 17577 67,100 30436 54,800 24857 38,750 17577 57,500 26082 99,600 45178 81,300 36878 57,500 26082
The above Working Load Limits are based upon using chain having a working load equal to that shown in column for single leg. Courtesy of The Crosby Group WIRE ROPE RATED CAPACITY (Approx.) Single-Part Rope Body Size Inch mm 12.7 14.3 15.9 19.0 22.2 25.4 28.6 31.7 34.9 38.1 41.3 44.4 47.6 50.8 1 Sling Vertical 2 Legs 60 2 Legs 45 2 Legs 30
2 9 16 5 8 3 4 7 8
1 118 114 138 112 158 134 178 2
Tons* 1.8 2.3 2.8 3.9 5.1 6.7 8.4 10.0 12.0 15.0 17.0 20.0 22.0 26.0
mt Tons* 1.6 3.2 2.1 2.5 3.5 4.6 6.1 7.6 9.1 10.9 13.6 15.4 18.1 20.0 23.6 4.0 4.8 6.8 8.9 11.0 14.0 18.0 21.0 25.0 30.0 34.0 39.0 44.0
mt 2.9 3.6 4.4 6.2 8.1 10.0 12.7 16.3 19.0 22.7 27.2 30.8 35.4 40.0
Tons* 2.6 3.2 4.0 5.5 7.3 9.4 12.0 15.0 17.0 21.0 24.0 28.0 34.0 36.0
mt 2.4 2.9 3.6 5.0 6.6 8.5 10.9 13.6 15.4 19.0 21.8 25.4 30.8 32.6
Tons* 1.8 2.3 2.8 3.9 5.1 6.7 8.4 10.0 12.0 15.0 17.0 20.0 22.0 26.0
mt 1.6 2.1 2.5 3.5 4.6 6.1 7.6 9.1 10.9 13.6 15.4 18.1 20.0 23.6
226
Span
Load
Ft. 4
meters 1.219
In. 6 8 8
Lbs.
kg
1.829
6 6 8 8 10 10 12
6 8 8 10 10 12 12
1,398 634.1 2,490 1129 3,320 1506 5,184 2351 6,480 2939 9,330 4232
2.438
6 6 8 8 10 10 12
6 8 8 10 10 12 12
1,050 476.3 1,866 846.4 2,488 1128 3,888 1763 4,860 2204 7,000 3175 8,400 3810
228
TONS OF MATERIAL REQUIRED PER MILE FOR VARIOUS WIDTHS AND POUNDS PER SQUARE YARD
Lbs. Per Sq. Yd. 1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 WIDTH - FEET 1 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 20.5 23.5 26.4 29.3 58.7 88.0 117.3 146.7 176.0 205.3 234.7 264.0 293.3 2 0.6 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 41.1 46.9 52.8 58.7 117.3 176.0 234.7 293.3 352.0 410.7 469.3 528.0 586.7 3 0.9 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 61.6 70.4 79.2 88.0 176.0 264.0 352.0 440.0 528.0 616.0 704.0 792.0 880.0 4 1.2 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 82.1 93.9 105.6 117.3 234.7 352.0 469.3 586.7 704.0 821.3 938.7 1056.0 1173.3 5 1.5 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 88.0 102.7 117.3 132.0 146.7 293.3 440.0 586.7 733.3 880.0 1026.7 1173.3 1320.0 1466.7 6 1.8 3.5 5.3 7.0 8.8 10.6 12.3 14.1 15.8 17.6 35.2 52.8 70.4 88.0 105.6 123.2 140.8 158.4 176.0 352.0 528.0 704.0 880.0 1056.0 1232.0 1408.0 1584.0 1760.0 7 2.1 4.1 6.2 8.2 10.3 12.3 14.4 16.4 18.5 20.5 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 1437.3 1642.7 1848.0 2053.3 8 2.3 4.7 7.0 9.4 11.7 14.1 16.4 18.8 21.1 23.5 46.9 70.4 93.9 117.3 140.8 164.3 187.7 211.2 234.7 469.3 704.0 938.7 1173.3 1408.0 1642.7 1877.3 2112.0 2346.7 9 2.6 5.3 7.9 10.6 13.2 15.8 18.5 21.1 23.8 26.4 52.8 79.2 105.6 132.0 158.4 184.8 211.2 237.6 264.0 528.0 792.0 1056.0 1320.0 1584.0 1848.0 2112.0 2376.0 2640.0 10 2.9 5.9 8.8 11.7 14.7 17.6 20.5 23.5 26.4 29.3 58.7 88.0 117.3 146.7 176.0 205.3 234.7 264.0 293.3 586.7 880.0 1173.3 1466.7 1760.0 2053.3 2346.7 2640.0 2933.3 20 5.9 11.7 17.6 23.5 29.3 35.2 41.1 46.9 52.8 58.7 117.3 176.0 234.7 293.3 352.0 410.7 469.3 528.0 586.7 1173.3 1760.0 2346.7 2933.3 3520.0 4106.7 4693.3 5280.0 5866.7 30 8.8 17.6 26.4 35.2 44.0 52.8 61.5 70.4 79.2 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 6160.0 7040.0 7920.0 8800.0 40 11.7 23.5 35.2 46.9 58.7 70.4 82.1 93.9 105.6 117.3 234.7 352.0 469.3 586.7 704.0 821.3 938.7 1056.0 1173.3 2346.7 3520.0 4693.3 5866.7 7040.0 8213.3 9386.7 10560.0 11733.3 50 14.7 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 1026.7 1173.3 1320.0 1466.7 2933.3 4400.0 5866.7 7333.3 8800.0 10266.7 11733.3 13200.0 14666.7 60 17.6 35.2 52.8 70.4 88.0 105.6 123.2 140.8 158.4 176.0 352.0 527.9 704.0 880.0 1056.0 1232.0 1408.0 1584.0 1760.0 3520.0 5280.0 7040.0 8800.0 10560.0 12320.0 14080.0 15840.0 17600.0
( )( )( )
3 2000
5280 _____
R ____
Where = 0.2933 RW
w = Weight of material in tons per mile R = Rate of application in lbs. per sq. yd. W = Width of application in feet
APPROXIMATE CUBIC YARDS OF AGGREGATE REQUIRED FOR ONE MILE OF ROAD AT VARIOUS WIDTHS AND LOOSE DEPTHS(See Note)
Width of Road (Ft.) 1 8 9 10 12 14 15 16 18 20 22 24 26 28 30 40 Sq. Yds. Per Mile 587 4693 5280 5867 7040 8213 8800 9387 10560 11733 12907 14080 15253 16427 17600 23467 LOOSE DEPTH (Inches) 1 16 130 147 163 196 228 244 261 293 326 358 391 424 456 489 652 2 33 261 293 326 391 456 489 521 587 652 717 782 847 913 879 1304 3 49 391 440 489 587 685 733 782 880 978 1076 1173 1271 1369 1467 1956 4 65 521 587 652 782 912 977 1042 1173 1304 1434 1564 1694 1824 1956 2607 5 81 652 733 815 978 1141 1222 1304 1467 1630 1793 1956 2119 2282 2444 3259 6 98 782 880 978 1173 1369 1467 1564 1760 1956 2152 2347 2543 2738 2933 3911 7 114 913 1027 1141 1369 1597 1711 1827 2053 2281 2510 2738 2966 3194 3422 4563 8 130 1043 1173 1304 1565 1825 1955 2086 2347 2607 2868 3128 3388 3684 3911 5215 9 147 1173 1320 1467 1760 2054 2200 2347 2641 2933 3228 3521 3815 4108 4440 5867 10 163 1304 1467 1630 1956 2282 2445 2608 2933 3259 3586 3912 4238 4564 4889 6519
229
NOTE: 16.30 cubic yards1" deep, 1' wide and 1 mile long. To obtain the amount of material required for depth after compaction, increase the above figures 15% to 30% depending on the type and gradation of material.
230
APPROXIMATE WEIGHT IN POUNDS PER SQUARE YARD OF AGGREGATES OF VARYING DENSITIES AT VARIOUS DEPTHS
Density (Lbs. per Cu. Yd) 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 DEPTH (Inches) 1 41.7 44.4 47.2 50.0 52.8 55.6 58.3 61.1 63.9 66.7 69.4 72.2 75.0 77.8 80.6 83.3 86.1 88.9 91.7 94.4 97.2 100.0 102.8 2 83.3 88.9 94.5 100.0 105.5 111.1 116.7 122.2 127.8 133.3 138.9 144.4 150.0 155.5 161.1 166.7 172.2 177.8 183.3 188.9 194.4 200.0 205.5 3 125.0 133.3 141.6 150.0 158.3 166.7 175.0 183.3 191.7 200.0 208.3 216.7 225.0 233.3 241.7 250.0 258.3 266.7 275.0 283.3 291.7 300.0 308.3 4 166.7 177.8 188.9 200.0 211.1 222.2 233.3 244.4 255.5 266.7 277.8 288.9 300.0 311.1 322.2 333.3 344.4 355.5 366.7 377.8 388.9 400.0 411.1 5 208.3 222.2 236.1 250.0 263.9 277.8 291.7 305.6 319.5 333.3 347.2 361.1 375.0 388.9 402.8 416.7 430.6 444.5 458.3 472.2 486.1 500.0 513.9 6 250.0 266.7 283.3 300.0 316.7 333.3 350.0 366.7 383.3 400.0 416.7 433.3 450.0 466.7 483.3 500.0 516.7 533.3 550.0 566.7 583.3 600.0 626.7 7 291.7 311.0 330.4 350.0 369.4 388.9 408.3 427.8 447.2 466.7 486.1 505.6 525.0 544.4 563.9 563.3 602.8 622.2 641.7 661.1 680.6 700.0 719.4 8 333.3 355.5 377.8 400.0 422.2 444.4 466.7 488.9 511.1 533.3 555.5 577.8 600.0 622.2 644.4 666.7 688.9 711.1 733.3 755.5 777.8 800.0 822.2 9 375.0 400.0 425.0 450.0 475.0 500.0 525.5 550.0 575.0 600.0 625.0 650.0 675.0 700.0 725.0 750.0 775.0 800.0 825.0 850.0 875.0 900.0 925.0 10 416.6 444.4 472.2 500.0 527.8 555.6 583.4 611.1 638.9 666.7 694.4 722.2 750.0 777.8 805.6 833.3 861.2 888.9 944.4 944.4 972.2 1000.0 1027.8 12 500.0 533.3 566.7 600.0 633.3 666.7 733.3 733.3 766.6 800.0 833.3 866.7 900.0 933.3 966.7 1000.0 1033.3 1066.7 1133.3 1133.3 1166.7 1200.0 1233.3
NOTE: This table may be used to estimate the cubic content of slabs of greater thickness and area than those shown. Examples: To find the cubic content of a slab of 1000 sq. ft. area and 8" thickness, add the figures given under 6" and 2" for 1000 sq. ft. To find the cubic content of a slab 6" thickness and 1500 sq. ft. area, add the figures given for 1000 and 500 sq. ft. under 6" thickness.
231
232
238
NOTES:
239
NOTES:
240