A stone quarry typically produces the following products:
1. Large size blocks blasted from the quarry face, from approximately 0.5 m3 (approximately 0.36 tonne weight) to 1.25 m3 (approximately 5-6 tonne weight), are called rip rap or rock armour and are used in coastal and river flood defence schemes to shore up sea fronts and river banks.
2. Rubble drawn direct from the shot pile is called face fill and is used as large scale fill on construction sites.
3. Material screened immediately prior to primary crushing is called scalpings or grizzly which is again used as fill on construction sites.
4. The direct, unscreened output from a crusher contains a complete mix of sizes from dust up to the maximum size that the crusher can pass. Output from the primary and secondary crushers is fed, unscreened, to intermediate or separate stockpiles. Material drawn from these stockpiles is called crusher run and is used for construction fill.
5. Screened out fine material from the secondary crusher is called blinding. Some screens have multiple decks and can screen out several grades of blinding. As with crusher run, blinding materials contain a mix of sizes, from the maximum size that the screen mesh can pass, down to dust. Blinding, because it is finer than crusher run, is used for final shaping up of construction sub bases, particularly in road construction, where the sub base is the last unbound layer before coated materials are laid.
6. Screened aggregate (ballast) for concrete.
7. Screened aggregate is heated and mixed with bitumen, according to certain recipe proportions, to make different grades of bituminous macadams, or, mixed with sand, ground limestone filler and bitumen, to make hot rolled asphalt.
8. 32/50 is used for railway ballast and as filter media in water treatment plants (if the rock type is tough enough).
9. Most Category GC aggregates can be used as a trench fill drainage stone, as the void space between aggregate particles allows water to flow through.
10. If the rock quarried is resistant to the polishing action of vehicle tyres, aggregate of size 14/20 Gc 85/20, when coated with 1½% bitumen, is called pre-coated chippings or pre-coats. Such chippings go on the surface of the hot rolled asphalt which surfaces many roads in the British Isles. The chippings are distributed in a single layer direct onto the laid asphalt and rolled into it while it is still hot. The chippings help give the asphalt a rough surface texture, which together with the stone’s resistance to polishing, provides grip to the surface which allows vehicles to brake and stop safely.
11. Surface dressing is universally disliked by motorists due to the risk of broken windscreens or chipped paint from loose chippings. This usually happens when vehicles are driven too fast on freshly dressed roads. As with all road construction sites, drivers and their vehicles will be safe from accidents if all the traffic signs posted are obeyed. The treated road will be finally suction swept after the chippings have firmly bedded into the binder. Bedding-in usually takes a day or two.