A Nigerian quarry operator produces aggregates for use in road base, concrete and asphalt from granite. This operator has a original two stage crushing plant which consists of a primary (600×900mm) 24×36″ jaw crusher , two secondary (300×1300mm) 12×51″ finer jaw crusher. The most popularly required sizes of aggregate in the market are 0~3/16″ (stone dust), 3/16~1/2″, 1/2~3/4″ and 3/4~1″. In this fines requirement, the operator only get 60~70 tons of aggregate per hour. The existing crushing plant is unable to meet the increasing demand on the aggregate with fines requirement and today’s increasingly high standard on aggregate shape. This operator contacts with our company and hope to expand his quarry.
Crushing Plant Solution
According to this operator’s requirement on fines and aggregate shape, our company designs a three stage crushing plant which consists of a primary (900×1200mm) 36×48″ jaw crusher, one secondary S51″ cone crusher (standard type), and one S51″ cone crusher (short head type) in the tertiary section.
From this crushing plant, the operator can get a capacity of 240~260tph of aggregate with 0~3/16″ (stone dust), 3/16~1/2″, 1/2~3/4″ and 3/4~1” sizes
Benefit and Advantage
Bigger capacity
Because of the application of tertiary cone crusher with short head type, the client can get bigger capacity of aggregate with 3/16~1/2” and 1/2~3/4” sizes (the percentage can reach to 76% in all aggregate), the price for aggregate with these two sizes are higher in the market, so the client can get bigger profit from this stone crushing plant
Good shape
The aggregate produced by jaw crusher doesn’t have good shape, the percentage of aggregate with elongation and flakiness shape is about 33~38%, so the operator unable to obtain a good price in the market. When this new crushing plant put into production, the client get aggregate with good shape, the percentage of aggregate with elongation and flakiness shape is only 11~13%. Because of the good quality of aggregate, this client becomes the preferred aggregate supplier in local market.
Easy installation
Because of this client also purchased a complete set steel supporting structure for each equipment , so the installation for whole crushing plant become easy. Comparing with crushing plant which built on the concrete supporting structure, the installation period for the crushing plant with steel supporting structure reduces about 20 working days. Considering the cost for concrete and labor in Nigeria, actually, the investment for steel supporting structure is more cost-efficient than the concrete supporting structure.
Conclusion
From this new crushing plant, the quarry operator can get bigger capacity of aggregate with fine size and good shape comparing with the original crushing plant, it means that he can get bigger profit from the new crushing plant in the same manufacturing cost for aggregate.
Aggregates, Concrete & Cement
The US cement, concrete, and construction material industry includes more than 5,000 companies with combined annual revenue of about $50 billion. Major companies include Ash Grove Cement Company, Texas Industries, US Concrete, and Vulcan Materials, as well as the US operations of foreign companies such as Cemex (Mexico), CRH (Ireland), Holcim (Switzerland), FCC (Spain), and LaFarge (France). The industry includes about 150 cement manufacturing companies, 2,500 ready-mix concrete manufacturing companies, and about 2,700 companies that make concrete block, brick, pipe, and other concrete products.
How to Make Aggregate Concrete
Concrete is a mixture of cement, water and an aggregate material. The most common aggregates used to make concrete are sand and gravel. In essence, all concrete is aggregate concrete. Special decorative aggregates frequently used for exposed aggregate concrete and include a variety of decorative stones in many different colors. The decorative material is used in place of the common, and less expensive, gravel. The concrete is poured and the the surface washed of the top layer of concrete to expose the decorative aggregate in the concrete.
Instructions
1. Mix one part Portland cement, two parts sand and four parts decorative aggregate stone and mix in enough water to make the mixture the consistency of cookie dough. If the decorative aggregate is expensive, the concrete can be made with less expensive gravel and the decorative aggregate seeded on top of the concrete after it is poured.
2. Pour the concrete into the form, screed and smooth with a concrete float as with any other concrete application. If the aggregate is seeded, sprinkle the aggregate on top of the concrete as soon as it is level and use a concrete float to press the aggregate into the top of the concrete.
3. Spray an even coating of concrete surface retarder on the top of the concrete according to the manufacturer’s directions.
4. Wash the top layer of concrete off the poured concrete when the concrete has set up enough that you can walk on the concrete without creating an impression. Wet the concrete with water from a hose and scrub off the top layer with the bristles of a stiff broom.
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Aggregates for Concrete in Nigeria Case Study
Aggregates for Concrete in Nigeria Case Study
A Nigerian quarry operator produces aggregates for use in road base, concrete and asphalt from granite. This operator has a original two stage crushing plant which consists of a primary (600×900mm) 24×36″ jaw crusher , two secondary (300×1300mm) 12×51″ finer jaw crusher. The most popularly required sizes of aggregate in the market are 0~3/16″ (stone dust), 3/16~1/2″, 1/2~3/4″ and 3/4~1″. In this fines requirement, the operator only get 60~70 tons of aggregate per hour. The existing crushing plant is unable to meet the increasing demand on the aggregate with fines requirement and today’s increasingly high standard on aggregate shape. This operator contacts with our company and hope to expand his quarry.
Crushing Plant Solution
According to this operator’s requirement on fines and aggregate shape, our company designs a three stage crushing plant which consists of a primary (900×1200mm) 36×48″ jaw crusher, one secondary S51″ cone crusher (standard type), and one S51″ cone crusher (short head type) in the tertiary section.
From this crushing plant, the operator can get a capacity of 240~260tph of aggregate with 0~3/16″ (stone dust), 3/16~1/2″, 1/2~3/4″ and 3/4~1” sizes
Benefit and Advantage
Bigger capacity
Because of the application of tertiary cone crusher with short head type, the client can get bigger capacity of aggregate with 3/16~1/2” and 1/2~3/4” sizes (the percentage can reach to 76% in all aggregate), the price for aggregate with these two sizes are higher in the market, so the client can get bigger profit from this stone crushing plant
Good shape
The aggregate produced by jaw crusher doesn’t have good shape, the percentage of aggregate with elongation and flakiness shape is about 33~38%, so the operator unable to obtain a good price in the market. When this new crushing plant put into production, the client get aggregate with good shape, the percentage of aggregate with elongation and flakiness shape is only 11~13%. Because of the good quality of aggregate, this client becomes the preferred aggregate supplier in local market.
Easy installation
Because of this client also purchased a complete set steel supporting structure for each equipment , so the installation for whole crushing plant become easy. Comparing with crushing plant which built on the concrete supporting structure, the installation period for the crushing plant with steel supporting structure reduces about 20 working days. Considering the cost for concrete and labor in Nigeria, actually, the investment for steel supporting structure is more cost-efficient than the concrete supporting structure.
Conclusion
From this new crushing plant, the quarry operator can get bigger capacity of aggregate with fine size and good shape comparing with the original crushing plant, it means that he can get bigger profit from the new crushing plant in the same manufacturing cost for aggregate.
Aggregates, Concrete & Cement
The US cement, concrete, and construction material industry includes more than 5,000 companies with combined annual revenue of about $50 billion. Major companies include Ash Grove Cement Company, Texas Industries, US Concrete, and Vulcan Materials, as well as the US operations of foreign companies such as Cemex (Mexico), CRH (Ireland), Holcim (Switzerland), FCC (Spain), and LaFarge (France). The industry includes about 150 cement manufacturing companies, 2,500 ready-mix concrete manufacturing companies, and about 2,700 companies that make concrete block, brick, pipe, and other concrete products.
How to Make Aggregate Concrete
Concrete is a mixture of cement, water and an aggregate material. The most common aggregates used to make concrete are sand and gravel. In essence, all concrete is aggregate concrete. Special decorative aggregates frequently used for exposed aggregate concrete and include a variety of decorative stones in many different colors. The decorative material is used in place of the common, and less expensive, gravel. The concrete is poured and the the surface washed of the top layer of concrete to expose the decorative aggregate in the concrete.
Instructions
1. Mix one part Portland cement, two parts sand and four parts decorative aggregate stone and mix in enough water to make the mixture the consistency of cookie dough. If the decorative aggregate is expensive, the concrete can be made with less expensive gravel and the decorative aggregate seeded on top of the concrete after it is poured.
2. Pour the concrete into the form, screed and smooth with a concrete float as with any other concrete application. If the aggregate is seeded, sprinkle the aggregate on top of the concrete as soon as it is level and use a concrete float to press the aggregate into the top of the concrete.
3. Spray an even coating of concrete surface retarder on the top of the concrete according to the manufacturer’s directions.
4. Wash the top layer of concrete off the poured concrete when the concrete has set up enough that you can walk on the concrete without creating an impression. Wet the concrete with water from a hose and scrub off the top layer with the bristles of a stiff broom.