Kpi Jci Facts Figures Handbook

SECOND EDITION
FACTS and FIGURES

Astec companies
&
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
KPI/JCI 2.5M pg 1/04
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
RELATIVE WORLD PRODUCTION BY VALUE

Sand and gravel and crushed stone are the number one and two ranked mineral resource (exclusive of energy resources) world wide in terms of both amount and value.
stone sand & gravel
iron gold
copper
Courtesy of
USGS
FIGURE NO. 1
Modified after Lawatscheck, 1990
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
Horizontal Shaft Impactors (HSI)

Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 New Holland style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Horse Power Requirements

Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179-180 Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Horizontal Shaft Impactors (HSI) Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Jaw Crushers (Peak to Peak) . . . . . . . . . . . . . . . . . . . . . . 25, 27 Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Roll Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-65 Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . . . . 69
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,
191, 239, 240 6
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
Typical Gradation Curve

Gravel Deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Limestone Quarry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Vertical Shaft Impact crushers (VSI). . . . . . . . . . . . . . . . . 68-75 Washing Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 ASTM C-33, C-144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-89 Blade Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-97 Classifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-116 Coarse material washing . . . . . . . . . . . . . . . . . . . . . . . 91, 94-97 Controls (Spec-Select I, II and III) . . . . . . . . . . . . . . . . . 115-116 Dredge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Fine material washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-101 Fineness Modulus (FM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Gradation requirements . . . . . . . . . . . . . . . . . . . . . 84-86, 88-89 Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-93 Sand Equivalent test (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Screening and Washing plants. . . . . . . . . . . . . . . . . . . . 118-119 Weights and Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 World Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION ON THE INERT MINERAL (AGGREGATE) INDUSTRY

Modern civilization is based on the use of inert minerals for concrete and asphaltic products. In truth, aggregate production is the largest single extractive industry in the United States. In excess of 2.8 billion tons of sand, gravel and crushed rock are produced annually. Because aggregates play such a vital role in the continuing growth of the nation and the world, demand for all types can be expected to increase substantially in the years ahead. There is great romance about these commonplace minerals; the earth sciences tell us a compelling story of the evolution of the earths mantle and its minerals which man has found so valuable to the civilizing processes on his planet. Since the earliest Ice Age, erosion of the continental rock by earth, wind, rain and fire have resulted in fractions being carried down the mountains by wind and water, the grains settling in an almost natural grading process. Other natural events such as floods and upheavals caused rivers and streams to change courses, burying river beds that have become high production sand and gravel operations in our time. Evaporation, condensation, precipitate and chemical actions, percolation and fusions have formed other rock materials that have become valuable aggregates in modern times. Advancements in geology and technology aid the industry in its progress to greater knowledge about these building blocks of all ages and civilizations. Locating these minerals has become much easier, tooand just in time as recently the nation has acknowledged the state of neglect of hundreds of thousands of miles of state and county roads. The massive Interstate Program has dominated the expenditure of road - building funds at the expense of these rural highways, so that today there are vast amounts of repair, reclamation and replacement of roads to be done. And, of course, locating nearby sources of roadbed materials wherever possible will affect the economy of constructionand, in some cases, even the kind of construction as well.
8
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
SIEVE ANALYSIS ENVELOPE

Percent passing by weight
100
sie ve s
80 60 40 20
0 100 50 30 16 8 4 Standard sizes of square-mesh sieves
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
EXAMPLE OF ALLOWABLE GRADATION ZONE IMPORTANCE OF GRADATION CONCRETE

To improve workability of concrete, either the amount of water or the amount of fine particles must be increased. Since the water-to-cement ratio is governed by the strength required in the final cured concrete, any increase in the amount of water would increase the amount of cement in the mix. Since cement costs are much greater than aggregate, it is evident that varying the gradation is more economical. Most of the formula used for proportioning the components of the concrete have been worked out as the results of actual experimentation. They are based, however, on two fundamentals. 1. To obtain a sound concrete, all voids must be filled either with fine aggregates or cement paste. 2. To obtain a sound concrete, the surface of each aggregate particle should be covered with cement paste. An ideal mix is a balance between saving on cement paste by using fine aggregates to fill the voids, and the added paste required to cover the surfaces of these additional aggregate particles.
12
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"
Allowable Cumulative Min. Max. 0 0 0 10 30 55 80 92 100 10 35 55 75 90 98 100 FIGURE NO. 3
Sample Tested IndivCumuldual tive 0 0 4 11 27 28 18 8 4 4 15 42 70 88 96 100
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
TYPICAL GRADATION CURVES FOR GRAVEL DEPOSITS
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
TYPICAL GRADATION CURVES FOR LIMESTONE QUARRY RUN
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
PIONEER APRON FEEDERS
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
STANDARD HOPPER APPROXIMATE CAPACITIESAPRON FEEDERS

6 Ft Width 30" ( 762 mm) Apron Feeder Without Extension 30" ( 762 mm) Apron Feeder With Extension 36" ( 914 mm) Apron Feeder Without Extension 36" ( 914 mm) Apron Feeder With Extension 42" ( 1067 mm) Apron Feeder Without Extension 42" ( 1067 mm) Apron Feeder With Extension 48" ( 1219 mm) Apron Feeder Without Extension 48" ( 1219 mm) Apron Feeder With Extension Yd.3 2.1 3.3 2.4 3.6 2.6 3.9 1.83 m m3 1.6 2.5 1.8 2.8 2.0 3.0 8 Ft. Yd.3 3.2 5.8 3.6 6.3 3.9 6.8 4.4 7.4 2.44 m m3 2.4 4.4 2.8 4.8 3.0 5.2 3.4 5.6 10 Ft. Yd.3 4.3 8.3 4.8 9.0 5.3 9.7 5.8 10.5 3.05 m m3 3.3 6.4 3.7 6.9 4.0 7.4 4.4 8.0 12 Ft. Yd.3 5.4 10.8 6.0 11.7 6.6 12.6 7.3 13.6 3.66 m m3 4.1 8.2 4.6 8.9 5.0 9.6 5.6 10.4 14 Ft. Yd.3 7.2 14.5 7.9 15.6 8.8 16.7 4.27 m m3 5.5 11.1 6.0 11.8 6.7 12.8
RECIPROCATING PLATE FEEDERS

Model Number 25 RP 31 RP 30 RP 37 RP 36 RP 42 RP in. 24 30 30 36 36 42 Size mm 610 762 762 914 914 1067 Type of Service Standard Standard Heavy Duty Standard Heavy Duty Heavy Duty Approx. Capacity* at 60 RPM 100-200 TPH ( 90.7 - 181 mt/h) 150-300 TPH ( 136-272 (mt/h) 150-300 TPH ( 136-272 mt/h) 215-430 TPH ( 195-390 mt/h) 215-430 TPH ( 195-390 mt/h) 300-600 TPH ( 272-544 mt/h) Hopper Size Ft. Sq. Meters Sq. 6 6 6 7 7 7 1.83 1.83 1.83 2.14 2.14 2.14 Hopper Capacity Cu. Yards 1.7 1.7 1.7 2.6 2.6 2.6 Cu. Meters 1.3 1.3 1.3 1.99 1.99 1.99 Weight (With Hopper) 2050 lbs. 2165 lbs. 2550 lbs. 3175 lbs. 3950 lbs. 4710 lbs. 931 kg 983 kg 1158 kg 1441 kg 1793 kg 2136 kg
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
APPROXIMATE PER HOUR CAPACITIES OF PIONEER APRON FEEDERS ACCORDING TO WIDTH

30" Wide Tons 74 112 148 186 223 260 296 Yds3 80 120 160 200 240 280 320 36" Wide Ton 108 162 216 270 324 378 432 Yds3 109 164 218 273 327 382 436 42" Wide Tons 147 222 294 369 442 516 588 Yds3 143 214 284 357 427 500 572 48" Wide Tons 192 289 384 482 577 673 768 Yds3 222 333 444 555 667 778 888 60" Wide Tons 300 450 600 750 900 1050 1200 Yds3 320 480 650 800 960 1120 1280 72" Wide Tons 432 648 864 1080 1296 1512 1728
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.
.762 m Wide mt 67 102 134 169 202 236 269
.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
PIONEER VIBRATING FEEDERS
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
VIBRATING FEEDERSAPPROXIMATE CAPACITY*

30" (.76m) WIDE RPM 600 650 700 750 800 850 900 950 1000 TPH mt/h 36" (.91m) WIDE TPH mt/h 42" (1.07m) WIDE TPH mt/h 50" 1.27m) WIDE TPH 623 671 720 767 mt/h 568 611 656 698 60" (1.5m) WIDE TPH 828 898 967 1035 mt/h 754 818 881 943
270 290 305 325 345 365
246 264 278 296 314 332
315 337 360 382 404 427
287 307 328 348 368 389
473 507 541 575 609 642
431 462 493 524 555 585
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.
STANDARD HOPPER APPROXIMATE CAPACITIES VIBRATING FEEDERS

30" x 12' 30" x 12' 36" x 14' 36" x 14' 36" x 16' 36" x 16' 42" x 15' 42" x 15' 42" x 17' 42" x 17' 42" x 18' 42" x 18' 42" x 20' 42" x 20' 50" x 16' 50" x 16' 50" x 18' 50" x 18' 50" x 20' 50" x 20' 60" x 24' 60" x 24' Standard Feeder Size ( 762mm x 3.7m) Without Extension ( 762mm x 3.7m) With Extension ( 914mm x 4.3m) Without Extension ( 914mm x 4.3m) With Extension ( 914mm x 4.9m) Without Extension ( 914mm x 4.9m) With Extension (1067mm x 4.6m) Without Extension (1067mm x 4.6m) With Extension (1067mm x 5.2m) Without Extension (1067mm x 5.2m) With Extension (1067mm x 5.5m) Without Extension (1067mm x 5.5m) With Extension (1067mm x 6.2m) Without Extension (1067mm x 6.2m) With Extension (1270mm x 4.9m) Without Extension (1270mm x 4.9m) With Extension (1270mm x 5.5m) Without Extension (1270mm x 5.5m) With Extension (1270mm x 6.1m) Without Extension (1270mm x 6.1m) With Extension (1524mm x 7.3m) Without Extension (1524mm x 7.3m) With Extension Yds.3 5.5 7.2 7.2 12.6 8.2 14.4 9.0 18.0 10.2 20.4 10.0 21.6 12.0 24.0 11.0 21.6 12.6 24.3 14.0 27.0 19.6 43.0 M3 4.2 5.5 5.5 9.6 6.3 11.0 6.9 13.8 7.8 15.6 8.2 16.5 9.2 18.4 8.4 16.5 9.6 18.6 10.7 20.6 15.0 32.9
20
BELT FEEDER CAPACITY (TPH)
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
Belt Speed FPM

10 30 34 38 41 45 49 53 40 45 50 55 60 65 70 50 56 62 69 75 81 87 20 60 68 75 83 90 98 105 80 90 100 110 120 130 140 100 113 125 137 150 162 175 30 90 101 113 124 135 146 158 120 135 150 165 180 195 210 150 169 187 206 225 244 262 40 120 135 150 168 180 195 210 160 180 200 220 240 260 280 200 225 250 275 300 325 350 50 150 169 188 206 225 244 262 200 225 250 275 300 325 350 250 281 312 344 375 406 437 60 180 203 225 248 270 293 315 240 270 300 330 360 390 420 300 338 375 412 450 487 525
NOTE: Capacities based on 100 lb./cu. ft. material
21
PIONEER JAW CRUSHING PLANTS
Rubber Tire Mounted
Track Mounted
Stationary
22
23
PIONEER JAW CRUSHERS APPROXIMATE JAW CRUSHERS GRADATIONOPEN CIRCUIT

Test Sieve Sizes (in.) 12" 10" 8" 7" 6" 5" 4" 3" 212" 2" 112" 114" 1"
3 3
APPROXIMATE GRADATIONS AT PEAK TO PEAK CLOSED SIDE SETTINGS
Test Sieve
4"
1" 25.4 mm
114"
112"
2"
212"
3"
312"
4" 102 mm
5" 127 mm
6" 152 mm 100
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
31.8 38.1 50.8 mm mm mm
63.5 76.2 89.1 mm mm 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" 2" 8" 4"
#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
LEGENDARY JAW CRUSHERSHORSEPOWER REQUIRED AND APPROXIMATE CAPACITIES IN TPH

SIZE HP Required (Minimum)
3
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
63 95 142 86 124 165 188 213 290
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
239 378 313 530 407 407 438
273 433 357 610 465 465 500
690 522 522 562
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
PIONEER VANGUARD JAW CRUSHERS

HORSEPOWER REQUIRED AND APPROXIMATE CAPACITIES IN TPH
SIZE HP Required (Minimum)
3
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
19 Elect Diesel mm 2650 3055 3144 3165

**
150 200 150 200 200 250
190 250 190 250 250 310
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
PIONEER PRIMARY IMPACT CRUSHERS (New Holland Style)
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
Close Normal Setting Setting
Close Normal Close Setting Setting Setting 100 97 100 96 90 77 64 57 50 41 32 26 20 17 12 8 5 3 2 90 75 66 56 48 43 38 31 24 19 14 12 8 5 3 2 1
Values are percent passing 100 98 89 80 67 56 50 44 37 28 23 17 15 10 6 4 3 2
4" 1 2" 3 8" 1 4"

3
#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"
600-900 600-1200 545-1091
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
PIONEER ANDREAS STYLE IMPACT CRUSHERS
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
PIONEER ANDREAS IMPACT CRUSHERS HORIZONTAL SHAFT IMPACT CRUSHER

Recommended HP Size 5260 4250 4233 Electric 300 150-200 100 Diesel 450 260 150 Approx. Capacities* TPH 250-350 125-225 75-140 mt/h 227-318 113-204 68-127
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"
Minimum Apron Setting 1" 1" 1"
Approximate Output Gradations-Open Circuit

100% 90% 80%
APRONS: Upper @ 4" Lower @ 2"
8000 fpm
% Cumulative Passing
70% 60% 50% 40% 30% 20% 10% 0% 50 mesh 8 mesh 1" 3" 10"12"
6500 fpm 5250 fpm
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
KODIAK AND LS CONE CRUSHER NOTES

1. Capacities and product gradations produced by cone crushers will be affected by the method of feeding, characteristics of the material fed, speed of the machine, power applied, and other factors. Hardness, compressive strength, mineral content, grain structure, plasticity, size and shape of feed particles, moisture content, and other characteristics of the material also affect production capacities and gradations. 2. Gradations and capacities shown are based on a typical well graded choke feed to the crusher. Well graded feed is considered to be 90% - 100% passing the closed side feed opening, 40% - 60% passing the midpoint of the crushing chamber on the closed side (average of the closed side feed opening and closed side setting), and 0 - 10% passing the closed side setting. Choke feed is considered to be material located 360 degrees around the crushing head and approximately 6" above the mantle nut. 3. Maximum feed size is the average of the open side feed opening and closed side feed opening. 4. A general rule of thumb for applying cone crushers is the reduction ratio. A crusher with coarse style liners would typically have a 6 to 1 reduction ratio. Thus, with a 34" closed side setting the maximum feed would be 6 x 34 or 4.5 inches. Reduction ratios of 8 to 1 may be possible in certain coarse crushing applications. Fine liner configurations typically have reduction ratios of 4:1 to 6:1. 5. Minimum closed side setting may be greater than published settings since it is not a fixed dimension. It will vary depending on crushing conditions, the compressive strength of the material being crushed, and stage of reduction. The actual minimum closed side setting is that setting just before the bowl assembly lifts minutely against the factory recommended pressurized hydraulic relief system. Operating the crusher at above the factory recommended relief pressure will void the warranty, as will operating the crusher in a relief mode (bowl float).
32
KODIAK AND LS CONE CRUSHERS
KODIAK 300 CONE
1400 LS Cone
33
KODIAK OPERATING PARAMETERS

The following list outlines successful operating parameters for the Kodiak line of crushers. These are not prioritized in any order of importance. Material 1. Material with a compressive strength greater than 40,000 pounds per square inch should be reviewed and approved in advance by the factory. 2. No more than 10% of the total volume of feed material is sized less than the crusher closed side setting. 3. The crusher feed material conforms to the recommended feed size on at least two sides. 4. Moisture content of material below 5%. 5. Feed gradation remains uniform. 6. Clay or plastic material in crusher feed is limited to prevent the formation of compacted material or pancakes being created. Mechanical 1. Crusher operates at factory recommended tramp iron relief pressures without bowl float. 2. Crusher support structure is level and evenly supported across all four corners. In addition the support structure provides adequate strength to resist static and dynamic loads. 3. Crusher is operated only when all electrical, lubrication and hydraulic systems are correctly adjusted and functioning properly. 4. Lubrication low flow warning system functions correctly. 5. Lubrication oil filter functions properly and shows adequate filtering capacity on its indicator. 6. Crusher drive belts are in good condition and tensioned to factory specifications. 7. Crusher lubrication reservoir is full of lubricant that meets factory requird specifications. 8. Any welding on the crusher or support structure is grounded directly at the weld location. 9. Crusher input shaft rotates in the correct direction. 10. Manganese wear liners are replaced at the end of their expected life and before coming loose or devleoping cracks.
34
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
KODIAK 300 CONE CRUSHER PROJECTED CAPACITY AND GRADATION CHARTS

Projected Open Circuit Capacitites in tons-per-hour
1
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
Projected Closed Circuit Capacitites in tons-per-hour

3
8"
2"
8"
4"
8"
1" 25.4 mm
21% 270-330 213-261
114" 32 mm
28% 310-385 223-277
9.52 mm 15% 130-165 110-140
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.
KODIAK 300 CONE CRUSHER GRADATION CHART

Crusher Closed Side Setting Prod- 5 16" 38" 716" 12" 58" 34" 78" 1" 114" 112" 134" 2" uct Size 7.94 9.52 11.11 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8
mm 4" 3 2" 3" 234" 212" 2 4" 2" 134" 112" 1 4" 1"
7 3 5 1 3 5 1 1 1
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
96 90 86 81 74 65 55 45 38 29 25 21 18 16 12 10 9 7 6 4 3 2 1.5 1 0.8 0.5 0.3
8" 4" 8" 100 2" 8"

99 91 85 74 58 50 40 35 28 21 18 14 11 8
16"
1
4"
4M
5
32"
8M 10M 16M 30M 40M 50M 100M 200M
Estimated product gradation percentages at setting shown. 37
KODIAK 300 MANGANESE CONFIGURATION KODIAK 300 Coarse Chamber
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.)
KODIAK 300 Medium Chamber with Feed Slots

Bowl Liner: 456075 Mantle: 456071 All Dimensions in inches A B C Max. Feed Material 712 912 114 712 714 914 1 6 7 918 514 718 8 3 7 9 4 412 Product Range: 34" to 134" 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.) 38
KODIAK 300 Medium Chamber
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.)
KODIAK 300 Medium Fine Chamber
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
KODIAK 300 Fine Chamber
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
JCI KODIAK 300 V-BELT DRIVE DATA SINGLE MOTOR

1200 RPM MOTOR 300 HP SINGLE
CRUSHER SHEAVE HUB MOTOR SHEAVE BORE SHEAVE HUB
LINERS
PINION SPEED
SHEAVE
COARSE MEDIUM FINE MED/FINE EX/FINE
850 RPM 900 RPM 950 RPM
10-8V-24.8 10-8V-24.8 10-8V-24.8
N N M
312 312 312
10-8V-18.0 10-8V-19.0 10-8V-20.0
M M M
41
42
KODIAK 400 CONE CRUSHER PROJECTED CAPACITY AND GRADATION CHARTS

Open Circuit Capacitites in tons-per-hour
1
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
Closed Circuit Capacitites in tons-per-hour

3
8"
2"
8"
4"
8"
1" 25.4 mm
21% 340-425 269-336
114" 32 mm
28% 405-505 292-364
9.52 mm 15% 165-200 140-170
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
KODIAK 400 CONE CRUSHER GRADATION CHART

mm 4" 3 2" 3" 234" 212" 2 4" 2" 134" 112" 1 4" 1"
7 3 5 1 3 5 1 1 1
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
96 90 86 81 74 65 55 45 38 29 25 21 18 16 12 10 9 7 6 4 3 2 1.5 1 0.8 0.5 0.3
8" 4" 8" 100 2" 8"

99 91 85 74 58 50 40 35 28 21 18 14 11 8
16"
1
4"
4M
5
32"
8M 10M 16M 30M 40M 50M 100M 200M
Estimated product gradation percentages at setting shown.
43
KODIAK 400 MANGANESE CONFIGURATION KODIAK 400 Coarse Chamber
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.)
KODIAK 400 Medium Chamber with Feed Slots

Bowl Liner: 546239 Mantle: 546034 All Dimensions in inches A B C Max. Feed Material 81116 10316 114 912 812 10 1 7 7 978 514 838 8 3 814 934 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.) 44
KODIAK 400 Medium Chamber
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.)
KODIAK 400 Medium Fine Chamber
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
KODIAK 400 Fine Chamber
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.)
KODIAK 400 Extra Fine Chamber
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
JCI KODIAK 400 V-BELT DRIVE DATA DUAL MOTOR

1200 RPM MOTOR 200 HP SINGLE WEG 586/7 TOSHIBA N587UZ
CRUSHER SHEAVE SHEAVE HUB MOTOR SHEAVE HUB BORE TOS WEG DRIVE NUMBER TOSH. DRIVE NUMBER
LINERS
PINION SPEED
BORE
SHEAVE
BORE WEG
12-8V-24.8 12-8V-24.8 12-8V-24.8
N N N
412 4 2 412
1
6-8V-18.0 6-8V-19.0 6-8V-20.0
J J M
378 3 8 378
7
358 358 358
701413 701103 701412
47
48
1200 LS / 1400 LS CONE CRUSHER PROJECTED CAPACITY AND GRADATION CHARTS

Open Circuit Capacitites in tons-per-hour
1
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
Closed Circuit Capacitites in tons-per-hour

1
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
1200 LS / 1400 LS CONE CRUSHER GRADATION CHART

mm 4" 3 2" 3" 234" 212" 2 4" 2" 134" 112" 1 4" 1"
7 3 5 1 3 5 1 1 1
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
96 90 86 81 74 65 55 45 38 29 25 21 18 16 12 10 9 7 6 4 3 2 1.5 1 0.8 0.5 0.3
8" 4" 8" 2" 100 8"

91 85 74 58 50 40 35 28 20 18 14 11 8
16"
1
4"
4M
5
32"
8M 10M 16M 30M 40M 50M 100M 200M
Estimated product gradation percentages at setting shown. 49
LS SERIES CRUSHER MANGANESE CONFIGURATIONS 1200LS Enlarged Feed Coarse Chamber

Bowl Liner: 450127 All Dimensions in inches Mantle: 450263 A B C Max. Feed Material 10 2 938 834 3 1 1 9 2 1 2 9 8 8 818 914 114 818 778 9 1 412 Product Range: 1" to 2" Minus Pinion Speed: 750 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.)
1200LS Coarse Chamber
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
1200LS Medium Fine Chamber
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
JCI 1200LS V-BELT DRIVE DATA SINGLE MOTOR

PINION SPEED
SHEAVE
750 RPM 800 RPM 850 RPM 900 RPM
6-8V-24.8 6-8V-24.8 6-8V-24.8 6-8V-24.8
M M M M
21516 21516 21516 21516
6-8V-16.0 6-8V-17.0 6-8V-18.0 6-8V-19.0
J J J J

LINERS
PINION SPEED
SHEAVE
725 RPM 775 RPM 825 RPM 875 RPM
8-8V-30 8-8V-30 8-8V-30 8-8V-24.8
N N N N
8-8V-12.5 8-8V-13.2 8-8V-14.0 8-8V-12.5
J J J J
1400LS Coarse Chamber
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.)
1400LS Medium Chamber
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
1400LS Medium Fine Chamber
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.)
1400LS Fine Chamber
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
JCI 1400LS V-BELT DRIVE DATA SINGLE MOTOR

LINERS
PINION SPEED
SHEAVE
COARSE MEDIUM MED/FINE FINE X/FINE
750 RPM 800 RPM 850 RPM 900 RPM 950 RPM
10-8V-24.8 10-8V-24.8 10-8V-24.8 10-8V-24.8 10-8V-24.8
N N N N N
312 312 312 312 312
10-8V-16.0 10-8V-17.0 10-8V-18.0 10-8V-19.0 10-8V-20.0
M M M M M

LINERS
PINION SPEED
SHEAVE
725 RPM 775 RPM 825 RPM 875 RPM
12-8V-30.0 12-8V-30.0 12-8V-30.0 12-8V-24.8
P P P N
12-8V-12.5 12-8V-13.2 12-8V-14.0 12-8V-12.5
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
Open Cycle Capacity TPH mt/h
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
1" 114" 112" 134" 2" 214"
248 101116 256 101516 262 268 11316 11716
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
Test Sieve Sizes mm 127 102 76 64 51 38 32 25 19 13 10 6 #4 #8 #16 #30 #50 #100
100 95 83 55 39 30 25 19 15 11 8 4
97 90 75 45 34 27 22 16 12 9 6 2
4" 2" 8" 4"
#4 #8 #16 #40 #50 #100
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
Open Cycle Capacity TPH mt/h
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"
1" 114" 112" 134" 2"
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
Values Shown Are Percent Passing 100 100 100 95 86 75 42 28 23 17 12 8 5 95 86 75 56 32 27 21 16 11 8 4 95 83 75 56 41 31 26 20 15 11 8 4
1" 25 mm 100 94 90 75 54 46 35 30 24 19 14 11 8 5 2
Test Sieve Sizes mm 51 38 32 25 19 16 13 10 6 #4 #8 #16 #30 #50 #100
100 97 90 75 60 45 36 28 23 17 13 10 6 2
4" 8" 2" 8" 4"
#4 #8 #16 #30 #50 #100
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
in. 3 " 8 1 " 2 5 " 8 3 " 4 7 " 8 1"
mm 10 13 16 19 22 25
in.
mm
in.
mm
31116 378 4116 414
94 98 103 108
5316 5516 512 558
132 135 140 143
in. 218 214 238 212
mm 54 57 60 64
in. 312 358 334 378
mm 89 92 95 98
TPH 150-190 160-205 175-225 195-250 210-270 230-295
mt/h 136-172 145-186 159-204 177-227 190-245 209-268
TPH 120-150 130-165 140-180 155-200 170-215 185-235
mt/h 109-136 118-150 127-163 141-181 154-195 168-213
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
in. 3 " 8 1 " 2 5 " 8 3 " 4 7 " 8 1"
mm 10 13 16 19 22 25
in. 358 334 378 4 418
mm 92 95 98 102 105
in. 458 434 478 5 518
mm 117 121 124 127 130
in. 178 2 218 214
mm 48 51 54 57
in. 318 314 338 312
mm 79 82 86 89
TPH 105-135 115-150 125-165 140-180 155-200 170-215
mt/h 95-122 104-136 113-150 127-163 141-181 154-195
TPH 85-110 90-120 100-130 110-145 125-160 135-170
mt/h 77-100 82-109 91-118 100-132 113-145 122-154
MAGNA CONE CRUSHER NOTES

1. Capacities and product gradations produced by cone crushers will be affected by the method of feeding, characteristics of the material fed, speed of the machine, power applied, and other factors. Properly controlled, continuous feeding of recommended size material uniformly around the feed opening of a cone crusher is essential for maximum production. Hardness, compressive strength, mineral content, grain structure, plasticity, size and shape of feed particles, moisture content, and other characteristics of the material affect production capacities and gradations. 2. Minimum closed side setting may be greater than listed since it is not a fixed dimension. It will vary depending on crushing conditions, the compressive strength of the material being crushed, and stage of reduction. The actual closed side settings is that setting just before the bowl assembly lifts minutely against the factory recommended pressurized hydraulic relief system. Operating the crusher at above the factory recommended relief pressure will void the warranty, as will operating the crusher in a relief mode. 3. Total TPH through crusher including recirculating load. 4. Net TPH of product in closed cycle. Capacity based on 20% recirculating load. Screen opening for closed cycle must be something larger than crusher CSS to maintain recirculating load to maximum of 20%.
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
Values Shown are Per Cent Passing
85 85 85 85 85 85 85 85 85 85 61 31 16 9 6 4 58 39 20 12 7 4 3 65 41 26 16 9 5 3 2 60 40 24 18 12 7 4 3 2 65 40 27 19 15 10 6 3 2 1 70 50 29 22 16 13 8 5 3 2 1 70 52 36 24 19 14 11 7 4 3 2 1 62 50 38 27 20 15 11 9 6 3 2 1 0.5 69 50 40 31 24 16 13 9 7 5 2 1 0.5 0 70 54 37 31 25 19 14 11 8 6 4 2 1 0.5 0
63 50 36 26 22 17 14 10 8 5 4 3 2 1 0.5 0
4" 2" 8" 4"
#4 #8 #16 #30 #50 #100
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
4" 2" 8" 4" 100

80 40 18 11 7 4
#4 #8 #16 #30 #50 #100
Gradation result may be varied to greater fines content by increasing feed and corresponding horsepower.
61
PIONEER TWIN ROLL CRUSHERS RECOMMENDED HP

Size 2416 3018 3024 3030 4022 4030 4240 5424 5536 Electric 50 100 125 200 150 250 300 250 350 Diesel (Continuous) 75 150 175 300 200 325 400 325 475
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.
MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES)

Roll Setting 24" Dia. Rolls
1 3
30" Dia. Rolls

1 3
40" or 42" Dia. Rolls

5 1
54" or 55" Dia. Rolls

3
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
1 112 2 238 3 2 4 312
1 4 178 212 278 318 334 438 5
118 112 214 3 338 3 3 4 412 514 6
*With smooth shells No beads Bead one shell 62
Bead two shells
PIONEER TWIN ROLL CRUSHERS RECOMMENDED HP

Size 2416 3018 3024 3030 4022 4030 4240 5424 5536 Electric 50 100 125 200 150 250 300 250 350 Diesel (Continuous) 75 150 175 300 200 325 400 325 475
APPROXIMATE CAPACITIES IN MT/H* FOR OPEN CIRCUIT (Use 85 percent of these values in closed circuit)
Roll Settings 6.35 12.7 19.0 25.4 31.7 38.1 50.8 63.5 76.2 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.
MAXIMUM FEED SIZE VS. ROLL SETTING* (MILLIMETERS)

1016 mm or 1372 mm or Roll 610 mm 762 mm 1066 mm 1397 mm Setting Dia. Rolls Dia.Rolls Dia. Rolls Dia. Rolls 6.35 12.7 12.7 15.9 19.0 9.52 19.0 19.0 25.4 28.8 12.7 25.4 25.4 31.7 38.1 19.0 38.1 38.1 47.6 57.1 25.4 50.8 50.8 63.5 76.2 31.7 60.3 60.3 73.0 85.7 38.1 69.8 69.8 79.4 95.2 50.8 88.9 95.2 114 63.5 111 133 76.2 127 152 *With smooth shells No beads Bead one shell Bead two shells 63
PIONEER TRIPLE ROLL CRUSHERS RECOMMENDED HP

Size 3018 3024 3030 4022 4030 4240 5424 5536 Electric 125 150 250 200 300 400 300 450 Diesel (Continuous) 175 200 375 275 400 525 400 600
APPROXIMATE CAPACITIES IN TPH* FOR OPEN CIRCUITSINGLE FEED

(Use 85 percent of these values in closed circuit single feed only) Roll Settings Size
1
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.
MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES)

Smaller Setting
1 3 1
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
*With smooth shells No beads Bead two shells 64
Bead three shells
PIONEER TRIPLE ROLL CRUSHERS RECOMMENDED HP

Size 3018 3024 3030 4022 4030 4240 5424 5536 Electric 125 150 250 200 300 400 300 450 Diesel (Continuous) 175 200 375 275 400 525 400 600
APPROXIMATE CAPACITIES IN MT/H* FOR OPEN CIRCUITSINGLE FEED

(Use 85 percent of these values in closed circuit single feed only) Roll Settings (mm) Size 6.35 12.7 19.0 25.4 31.7 38.1 50.8 63.5
3018 33 68 102 136 170 204 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.
MAXIMUM FEED SIZE VS. ROLL SETTING* (MM)

Smaller Setting 6.35 9.52 12.7 19.0 25.4 31.7 38.1 50.8 63.5 762 mm Dia. Rolls Larger Max. Setting Feed 12.7 25.4 19.0 38.1 25.4 50.8 38.1 76.2 47.6 88.9 50.8 88.9 50.8 88.9 1016 mm or 1066 mm 1372 mm or 1397 mm Dia. Rolls Dia. Rolls Larger Max. Larger Max Setting Feed Setting Feed 14.3 31.7 15.9 38.1 20.6 47.6 23.8 57.1 28.6 63.5 31.7 76.2 42.9 95.2 46.0 114 57.1 127 61.9 152 63.5 127 69.8 152 69.8 127 76.2 152 76.2 127 76.2 152 76.2 127 76.2 152 Bead three shells 65
*With smooth shells No beads Bead two shells
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"
EXAMPLE: (4030 Triple Roll)
(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
DETAIL DATA FOR ROLL CRUSHER PERFORMANCE (TWIN ROLLS)

No. of Teeth Unit 2416 3018 3024 3030 4022 Pinion 15 17 17 19 18 Gear 68 82 82 73 103 Countershaft RPM 270 325 325 300 325 Shell FPM 346 530 530 623 600 Rubber Star Gears Tires Working Working Centers, Centers, In. Inches 2214-2534 2814-33 30-32 2814-33 (7 x 18) 30-32 (7 x 18) 1 39-42 37 2-4212 (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) 53-58 (12 x 36) No. of Springs Per Roll 2 2 2 8 8
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
DETAIL DATA FOR ROLL CRUSHER PERFORMANCE (TRIPLE ROLLS)

No. of Teeth Unit 3018 Pinion 17 Gear 82 Countershaft RPM 325 Shell FPM 530 Rubber Star Gears Tires Working Working Centers, Centers, In. Inches 2814-33 No. of Springs Per Roll 2 2 2 2 8 8 8 8 8 8 12 8 8 8 8 12
3024 3030 4022
18 19 19
82 73 91
325 300 310
555 623 680
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
53-58 (12 x 36)
67
PIONEER SPOKANE VERTICAL SHAFT IMPACT CRUSHER OPERATION
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
PIONEER VERTICAL SHAFT IMPACT CRUSHERSpecifications and Production Characteristics

Maximum Feed Size (1) Model 1500 (H) 1500 (A) 2500 (H) 2500 (A) 82 4500 (H) 4500 (H) 4500 (A) 120 Inch 2 2 3 2 3 3 5 212 6 MM 50 50 75 50 75 75 125 63 150 Minimum Recommended Closed Circuit Mesh #16 #4 #16 #4 #16 4M
3
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
Max Feed Size Range Cubed Crusher Throughput
Model 4500 4-5" (100-125 mm) 300-450 TPH
Model 120 5-6" (125-150 mm) 300-500 TPH
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
1" Feed Feed Typical Output
Sieve Size mm 75mm 50mm 37.5mm 25mm 19mm 12.5mm 9.5mm 6.3mm 4.75mm 2mm 1.18mm 600uM 300uM 150uM 75uM
Typical Limestone in Standard Configuration

PRODUCING A COARSE GRADED MATERIAL, EMPHASIS ON CHIPS, POPCORN, AND DIMENSIONAL PRODUCTS
Maximum Feed Size: Cubed Model 1500H Model 2500H Model 82H 2" (50mm) 3" (75mm) 3" (75mm) Crusher Throughput Capacity 75-125 TPH 150-250 TPH 250-400 TPH
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
Models 1500H, 2500H, 82H 3" Feed Feed Typical Output 100% 98 95 87 79 68 57 46 37 26 17 11 7 5 4
2" Feed Typical Output
1" Feed Feed Typical Output
Sieve Size mm 75mm 50mm 37.5mm 25mm 19mm 12.5mm 9.5mm 6.3mm 4.75mm 2mm 1.18mm 600uM 300uM 150uM 75uM

PRODUCING A DENSE GRADED MATERIAL, EMPHASIS ON FINES FOR BASE, ASPHALT MATERIAL, SAND SUPPLEMENT, ETC.
Feeds: Typical feeds shown have been screened to take out product sized material, and are initial feed plus recirculating load. Outputs: These outputs show average values based on field experience crushing tough material, and indicate crusher output before screening product sized material out. Gradation change is due to increased impeller speed from 50% to 100% of maximum and a difference in impeller table configuration. Values will differ for each specific crushing application. 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.
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*
1" FEED SIZE APPLICATIONS Models 1500H, 2500H, 82H

Crushing 1" top feed size for chips, popcorn, fracture count, or a manufactured sweetener. Low Range Resulting from: tough feed material impeller speeds 50-80% of max. crusher choke-fed 3 or 4 shoe table High Range Resulting from: moderately tough to moderately friable feed material impeller speeds 80-100% of max crusher fed 85% of choke-feed rate, or less five shoe table
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
Models 1500A, 2500A, 4500A 1 2" Feed

1
Sieve Size mm 50mm 37.5mm 31mm 25mm 19mm 12.5mm 9.5mm 6.3mm 4.75mm 2mm 1.18mm 600uM 300uM 150uM 75uM
Fully Autogenous 100% Speed 100% 99 95 90 70 56 38 31 22 15 11 8 6 4
SemiAutogenous 100% Speed
Typical Sand and Gravel in Autogenous and Semi Autogenous Configuration

Maximum Feed Size: Cubed Model 1500A Model 2500A Model 4500A 2" 2" 212" Crusher Throughput Capacity 75-150 TPH 150-300 TPH 300-500 TPH
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.
VERTICAL SHAFT IMPACT CRUSHER CRUSHING CHAMBER TERMINOLOGY

FULLY AUTOGENOUS ROTOR & HYBRID ROCK SHELF Rock-on-rock crushing; rotor flings rock against bed of rock on outer hybrid rock shelf, and exposed portion of anvils lining the hybrid rock shelf for free-body impacting. Variable reduction ratios of 10:1 to 3:1. SEMI-AUTOGENOUS ROTOR & ANVIL Crushing chamber has autogenous rotor and standard stationary anvils for specialized crushing and materials problems; 112-2" feed sizes and variable reduction ratios of 10:1 to 3:1.
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
PIONEER HAMMERMILLS APPROXIMATE HAMMERMILL GRADATION OPEN CIRCUIT

Test Sieve Sizes (in.) 212" 2" 112" 114" 1" 3 " 4 1 " 2 3 " 8 1 " 4 #4 #8 #16 #30 #40 #60 #100 Grate Bar Selection Number 1 2 3 4 5 6 7 8 9 10 Test Sieve Sizes (mm) 63.5 50.8 38.1 31.8 25.4 19.1 12.7 9.53 6.35 #4 #8 #16 #30 #40 #60 #100
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
40-70 36-64 60-100 54-91
60-100 54-91 90-140 82-127
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
GRATE BAR SELECTION CHART FOR PRODUCT SIZES

5042 Hammermill
Single Pass Max. Feed 8" x 8" Desired Approx. Grate Bar Product Top Size Group*
1
Grate BarsSize and Number Required
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" 114" 112" 114" 114" 2" 2" 212"
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
Grate Bar Size
Included Angle
Grate Bar Size 1" 112" 2" 3"
Included Angle
4" 3 " 8 1 " 2 3 " 4
4034 Hammermill
Single Pass Max. Feed 5" x 5" Desired Approx. Grate Bar Product Top Size Group*
1
Grate BarsSize and Number Required
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" 114" 112" 114" 114" 2" 2" 212"
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
Grate Bar Size
Included Angle
Grate Bar Size
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
GRATE BAR SELECTION CHART FOR PRODUCT SIZES

5042 Hammermill
Single Pass Max. Feed 203 mm x 203 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 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
Grate Bar Size 6.35 mm 9.53 mm 12.7 mm 19.1 mm
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
Grate Bar Size 6.35 mm 9.53 mm 12.7 mm 19.1 mm
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
*FACTORS FOR CALCULATING SCREEN AREA**

Formula: Screening Area =
*Basic Operating Conditions Feed to screening deck contains 25% oversize and 40% halfsize Feed is granular free-flowing material Material weighs 100 lbs. per cu. ft. Operating slope of screen is: Inclined Screen 18 - 20 with flow rotation Horizontal Screen 0 Objective Screening Efficiency95% **Furnished by VSMA U = STPH Passing Specified Aperture
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
FACTOR B (Percent of Oversize in Feed to Deck)

% Oversize Factor B % Oversize Factor B % Oversize Factor B 5 10 15 20 25 1.21 1.13 1.08 1.02 1.00 40 .88 75 .58 45 .84 80 .53 50 .79 85 .50 55 .75 90 .46 60 .70 95 .33 30 .96 65 .66 35 .92 70 .62
FACTOR C (Percent of Halfsize in Feed to Deck)

% Halfsize Factor C % Halfsize Factor C % Halfsize Factor C 0 .40 35 .90 5 .45 10 .50 15 .55 20 .60 25 .70 30 .80
8" 3 4" 5 8" 1 2" 3 8" 1 4" 3 16" 1 8" 3 32" 1 16" 1 32"
40 45 50 55 1.00 1.10 1.20 1.30
60 65 1.40 1.55
70 75 80 85 90 1.70 1.85 2.00 2.20 2.40
FACTOR D (Deck Location)

Top 1.00 Second .90 Third .80
FACTOR H (Shape of Surface Opening)

Square . . . . . . . . . . 1.00 Short Slot (3 to 4 times Width) . . . . 1.15 Long Slot (More than 4 Times Width) . 1.20
FACTOR E (Wet Screening)

Opening 132" 116" 18" 316" 14" 38" 12" 34" 1" Factor E 1.00 1.25 2.00 2.50 2.00 1.75 1.40 1.30 1.25
FACTOR F (Material Weight)

Lbs./cu.ft. 150 125 100 90 80 75 70 60 50 30 Factor F 1.50 1.25 1.00 .90 .80 .75 .70 .60 .50 .30
FACTOR J (Efficiency)
95% 90% 85% 80% 75% 70% . . . . . . . . . . . . 1.00 . . . . . . . . . . . . 1.15 . . . . . . . . . . . . 1.35 . . . . . . . . . . . . 1.50 . . . . . . . . . . . . 1.70 . . . . . . . . . . . . 1.90
FACTOR G (Screen Surface Open Area)

Factor G = % Open Area of Surface Being Used % Open Area Indicated in Capacity
79
STANDARD WIRE MESH FOR VIBRATING SCREENS PIONEER STANDARDS

Space or Clear Opening Fractions of Inch 10 x 10 mesh* 8 x 8 mesh* 6 x 6 mesh* 5 x 5 mesh 4 x 4 mesh 3 x 3 mesh Decimals of Inch .07 09 .126 .153 .196 27 .3125 .375 .4375 .500 .625 .75 .8125 .875 1.0 1.125 1.25 1.375 1.5 1.75 2.0 2.25 2.5 2.75 Trilock Trilock Trilock Trilock Millimeters 1.78 2.29 3.20 3.89 4.98 6.86 7.94 9.52 11.1 12.7 15.9 19.0 20.6 22.2 25.4 28.6 31.7 34.9 38.1 44.4 50.8 57.1 63.5 69.8 3.17 x 50.8 4.76 x 76.2 6.35 x 76.2 9.52 x 102
5
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
16" 3 " 8 7 " 16 1 " 2 5 " 8 3 " 4 13 " 16 7 " 8

1" 118" 114" 138" 112" 134" 2" 214" 212" 234"
16" 5 " 16 5 " 16 3 " 8 3 " 8 7 " 16 7 " 16 7 " 16

12 10 9 7
8" x 2" 3 " x 3" 16 1 " x 3" 4 3 " x 4" 8
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.
STANDARD LENGTHS OF SCREEN CLOTHS AND CLAMP BARS

Length of Screen Deck Feet 6 8 10 12 14 16 Meters 1.83 2.44 3.05 3.66 4.27 4.88 Length of Screen Cloth Feet 6 8 10 6,6 6,8 8,8 Meters 1.83 2.44 3.05 1.83 , 1.83 1.83 , 2.44 2.44 , 2.44 6 4,4 4,6 6,6 6,4,4 Length of Clamp Bars Feet Meters 1.83 1.22 , 1.22 1.22 , 1.83 1.83 , 1.83 1.83 , 1.22 , 1.22
4 , 4 , 4 , 4 1.22 , 1.22 , 1.22 , 1.22
80
STANDARD REQUIREMENTS FOR CERTAIN SIZES OF U.S. STANDARD SIEVES

Size of Sieve Opening
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%
Diameters of Wire (Varies According to Differences in Size of Opening)
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.
SIEVES FOR TESTING PURPOSES

Screen or Sieve Designation 4" 3" 2" 112" 1" 3 4" 1 2" 3 8" 1 4" No.4 6 8 12 16 20 30 40 50 70 100 140 150 200 270 400 84 Nominal Opening Equivalents mm inches microns 101.6 76.2 50.8 38.1 25.4 19.1 12.7 9.52 6.35 4.76 0.187 4760 3.36 0.132 3360 2.38 0.0937 2380 1.68 0.0661 1680 1.19 0.0469 1190 0.84 0.0331 840 0.59 0.0232 590 0.42 0.0165 420 0.297 0.0117 297 0.210 0.0083 210 0.149 0.0059 149 0.105 0.0041 105 0.100 0.0039 100 0.074 0.0029 74 0.053 0.0021 53 0.037 0.0015 37
GRADING REQUIREMENTS FOR COARSE AGGREGATES

Amounts Finer than Each Laboratory Sieve (Square-Openings), Weight Percent Size Number 1 2 3 357 4 467 5 56 57 6 67 7 8 Normal Size (Sieves with Square Openings) 312 to 112 in. (90 to 37.5 mm) 2 2 to 1 2 in. (63 to 37.5 mm) 2 to 1 in. (50 to 25.0 mm) 2 in to No. 4 (50 to 4.75 mm) 1 3 1 2 to 4 in. (37.5 to 19.0 mm) 1 1 2 in to No. 4 (37.5 to 4.75 mm) 1 1 to 2 in. (25.0 to 12.5 mm) 3 1 to 8 in. (25.0 to 9.5 mm) 1 in. to No. 4 (25.0 to 4.75 mm) 3 3 4 to 8 in. (19.0 to 9.5 mm) 3 4 in. to No. 4 (19.0 to 4.75 mm) 1 2 in. to No. 4 (12.5 to 4.75 mm) 3 8 in. to No. 8 (9.5 to 2.36 mm)
1 1
4 in. (100 mm) 100
3 2 in. (90 mm) 90 - 100
3 in. (75 mm)
2 2 in (63 mm) 25 - 60
2 in. (50 mm)
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
2 in. (12.5 mm)
8 in. (9.5 mm)
No. 4 (4.75 mm)
No. 8 No. 16 (2.36 mm) (1.18 mm)
100
90 - 100 100 100
35 - 70 90 - 100 95 - 100 100 100
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
.0083 .0070 .0059
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
100 200 75 .0029 2.0 1.7
89
MM DECIMAL
.0937 .078 .066
.0083 .0070 .0059
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.
COARSE MATERIAL WASHING

In order to produce aggregate at the most economical cost, it is important to remove as soon as possible from the flow of material any size fraction that can be considered ready for use. The basic process consists of crushing oversize material, scrubbing or washing coatings or entrapped materials, sorting and dewatering. Beneficiation of some coarse aggregate fractions may be necessary. When scrubbing or washing of coarse material is required, it is generally a consideration of the material size, the type of dirt, clay or foreign material to be scrubbed and the Tons Per Hour rate needed that will determine the coarse material washing equipment to use.
91
SERIES 8000 LOG WASHERS
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.
KOLBERG LOG WASHERS

Model Capacity (TPH) Motor (HP) Water Reqd. (GPM) Maximum Feed Size (in.) Approx. Dead Load (lbs.) Approx. Live Load (lbs.)
8024-18 8036-30 8048-30 8048-35
25-60 85-125 125-225 125-225
40 100 150 200
25-250 50-500 100-800 100-800
3" 4" 5" 5"
12,500 34,000 47,500 53,000
20,500 75,000 90,000 95,500
93
SERIES 6000 COARSE MATERIAL WASHERS
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.
KOLBERG AGG PREPS

Capacity (TPH) 60-75 150-175 200-250 300-350 400-500 Motor (HP) 15 25 40 25 40 Water Reqd. (GPM) 300-400 400-600 500-700 700-900 800-1000 Approx. Dead Load (lbs.) 6,200 10,400 15,600 18,000 27,920 Approx. Live Load (lbs.) 11,200 21,900 43,600 41,000 81,000
Model 6024-15S 6036-19S 6048-23S 6036-19T 6048-23T
SINGLE SPIRAL CONFIGURATIONS:
TWIN SPIRAL CONFIGURATIONS:
NOTE: Two (2) motors required on twin units. 24" diameter unit offered only in single spiral configuration.
95
SERIES 6500 BLADEMILLS
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
FINE MATERIAL WASHING AND CLASSIFYING

INTRODUCTION
Aside from washing sand to remove dirt and silt, hydraulic methods are employed to size the material and to classify or separate it into the proper particle designation. After these steps, it is usual procedure to dewater the product. Washing aggregates to clean them is not new. However, much closer attention has been given to both the cleanliness and the gradation of the fines in construction aggregates. Thus has developed a new "art" in the processing of fine aggregates. This "art" requires more technical know-how and methods more precise than those usually associated with the mere washing of gravel and rock. At the same time, it has been necessary to advance the art in a practical way so as to produce material at a reasonable price. Screening is the best way to separate coarse aggregates into size ranges. With fine materials, however, screening on less than No. 8 mesh usually is impractical. This necessitates a split between 38" and #4 mesh putting everything finer into the category of requiring hydraulic separation for best gradation control. With hydraulic separation, a large amount of water is used. Here separation depends on the relative buoyancys of the grain particles and on their settling rates under specific conditions of water flow and turbulence. In some cases, separation depends on the relative specific gravity difference between the materials to be separated and the hydraulic medium. In a certain sense, this applies when water is used to separate particle sizes of sands. Perhaps it would be more apt to say this separation of sands is based on relative densities or that the process separates by gravity.
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
SERIES 5000 FINE MATERIAL WASHERS
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
100% 75% 50% 25%
15 20 30 50
2 5 10 25
0 0 3 8
101
KOLBERG SAND PREPS

RAKING & OVERFLOW CAPACITY TABLE
CAPACITY SINGLE/ % SCREW TWIN SPEED (TPH) (RPM) SPIRAL SPEED (RPM) MINIMUM OVERFLOW CAPACITIES MOTOR HP (GPM) REQD/ SINGLE/TWIN SPIRAL 100 MESH 150 MESH 200 MESH
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
7.5 5 5 3 10 10 7.5 5 15 10 7.5 5 20 15 10 7.5 20 15 10 7.5 30 25 15 10 30 25 20 15 40 30 25 15 60 50 30 15
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
2200/3600 1000/1800 550/950
5066-35
2400/4000 1100/2000 625/1000
5072-38
2600/4400 1250/2200 700/1200
NOTE: Two (2) motors required on twin units. *24" & 30" dia. units offered only in single spiral configuration.
102
KOLBERG SAND PREP WEIR OVERFLOW RATES

MODEL 5024-25S 5030-25S 5036-25S 5036-25T 5044-32S 5044-32T 5048-32S 5048-32T 5054-34S 5054-34T 5060-35S 5060-35T 5066-35S 5066-35T 5072-38S 5072-38T WEIR LENGTH 15'3" 15'9" 16'3" 19'9 22'0" 26'0" 22'3" 26'9" 26'0" 31'0" 26'6" 31'6" 27'3" 32'9" 27'9" 34'3"
1
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"
AVERAGE DEPTH OVER WEIR 1" 114"

500 550
134" 1205 1244 1284 1560 1738 2054

1650
2" 1449 1496 1544 1876 2090

2700
214" 1678 1733 1788 2173 2420 2860 2448

2900
212" 1983 2048 2113 2568 2860 3380 2893 3478 3380 4030 3445
3600
92 95
175
229 236
325
397 410 423

300 600
564 583
700
717 740 764 928 1034

1300
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
1430 1690 1446 1739

1800
676 579
825
1222 1046
1450
2470 2114 2541 2470

3200
334 401
525
823 990
900
1758 2113 2054 2449

2200
696 676
900
1257 1222
1600
2943 2860 3410 2915 3465 2998

4000
390 465
550
962 1147
1000
1690 2015 1723

1800
806 689
950
1457 1246 1481

1100
2945 2518 2993

2400
398 473
625
981 1166 1008

1000
2094 2489 2153 2587 2192 2706
819 709 852

700
2048 1771
2000
4095 3543 4258 3608

4400
409 491 416 514
1281 1539
1250
2589 3111
2600
1212 1027
1200
2129 1804
2200
3603 3053 3768
722 891
1304 1610
2636 3254
103
1267
2226
4453
CLASSIFICATION METHODS APPLIED TO FINE AGGREGATES

INTRODUCTION
Classification is the sizing of solid particles by means of settling. In classification, the settling is controlled so that the very fines, silts and clays will flow away with a stream of the water or liquid, while the coarse particles accumulate in a settled mass. Washing/classifying equipment is manufactured in many different configurations depending on the natural material characteristics and the end product(s) desired. Although, the general definition of aggregate classifying can be applied to coarse material (+38"), it is most commonly applied to the material passing 38". Included in the fine material classifying equipment are the sand screws, counter-current classifiers, sand drags and rakes, hydro-cyclones, hydro-classifiers, bowl classifiers, hydro-separators, density separators and scalping/classifying tanks. All the above mentioned classifiers except the scalping/classifying tank are generally single product machines which can only affect the gradation of the end product on the very fine side (the overflow separation size). This separation size, due to the mechanical means employed, is never a knife-edge separation. However, the aim of modern classification methods is to approach a clean-cut differentiation. Many material specifications today call for multiple sizing of sand with provisions for blending back to obtain the gradations required. It is rare to find the exact blend occurring naturally or to economically manufacture the blend to exact specifications. In either case, the accepted procedure is to screen out the fine material from which the sand specifications will be obtained. This material is processed in a water scalping/classifying tank for multiple separation by grain sizes or particle specific gravity. There is no mystery connected with classifying tanks. They are merely long settling basins capable of holding large quantities of water. The water and sand mix
104
(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.
CALCULATION OF SLURRY OR PULP

The following method of calculating slurry or pulp is quick, accurate and requires no reference tables. It may be used for any liquid-solid mixture. Basic equation, for a single substance or mixture: 4 GPM = TPH x SG For Water: GPM Water = TPH Water x 4 4 For Solids: GPM Solids = TPH Solids x SG Solids
105
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
HORIZONTAL TRAVEL OF FALLING SAND PARTICLES
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
DENSITYSPECIFIC GRAVITY RELATIONSHIP

FOR WATER SLURRY OF SAND, GRAVEL, QUARTZ OR LIMESTONE (SOLID S.G. 2.65-2.70)
0 2.0 10 20 30 40 50 60 70 80 2.0 DENSITY PERCENT SOLIDS WT 1 LITER SLURRY IN GRAMS 1000 FOR THE ABOVE MATERIALS
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
DENSITY % SOLIDS BY WEIGHT = 160 (G-1) G
1.8
FO R
1.7 SPECIFIC GRAVITY SLURRY OR PULP (G)
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
DENSITY PERCENT SOLIDS 1.0 0 10 20 30 40 50 60 70 80 1.0
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
SERIES 7000 SAND CLASSIFYING TANKS
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
Water and Slime Coarse Medium Fine Very Fine
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.
KOLBERG SAND SORTS

SIZE APPROX. DEAD LOAD (LBS) APPROX. LIVE LOAD (LBS) WATER CAPACITIES (GPM) 100 MESH 150 MESH 200 MESH NUMBER OF DISCHARGE STATIONS
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
KOLBERG SAND SORT WEIR OVERFLOW RATES

4"
1
2"
700
4"
AVERAGE DEPTH OVER WEIR 1" 114" 112" 1200 2300
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
1150 1440 1720 2010

1800
1690 2120
3200
2225
2800
2720 3400 4070 4750

3500
3360 4200 5040 5880 4400 5240 6080 6920 7760

8100
4400 5000 6000 7000 5250 6250 7250 8250 9250 10000
600
900
1000
1600
2800 3350 3920 2940

4100
720
950
1200
1800
2550
3500
840
950
1400 1050
1100
2960 2230 2650 3060 3500 3920

4200
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
4630 5180 5600
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
Mode of Operation Touch Screen Operator Interface
SSI Monochrome PLC
SSI & SSII Monochrome PLC
Printer Compatible Disc Download Optional Modem Hook-up Optional
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
SERIES 1800 SCREENING/WASHING PLANTS
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
KOLBERG 1800 SERIES SCREENING/WASHING PLANTS

Description Model 1814 Model 1822 Model 1830
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
5' x 14' 36" single 100 TPH 700 GPM
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
Yes Yes Yes Yes
Yes Yes Yes Yes
Yes Yes Yes Yes
Yes N/A Yes Yes N/A
Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes
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
JCI SCREENING THEORY

Screening is defined as a mechanical process which accomplishes a separation of particles on the basis of size. Particles are presented to a multitude of apertures in a screening surface and rejected if larger than the opening, or accepted and passed through if smaller. The material requiring separation, the feed, is delivered to one end of the screening surface. Assuming that the openings in the screening media are all the same size, movement of the material across the surface will produce two products. The material rejected by the apertures (overs) discharges over the far end, while the material accepted by the apertures (throughs) pass through the openings. As a single particle approaches the screening media, it could come into contact with the solid wire or plate that makes up the screen media, or pass completely through the open hole. If the size of the particle is relatively small when compared to the openings, there is a high degree of probability that it will pass through one of them before it reaches the end of the screen. Conversely, when the particle is relatively large, or close to the same size as the opening, there is a high degree of probability that it will pass over the entire screen and be rejected to the overs. If the movement of the particle is very rapid, it might bounce from wire to wire and never reach a aperture for sizing. The velocity of the particle, the incline of the screen, and the thickness of the wire all tend to reduce the effective dimensions of the openings and make accurate sizing more difficult. It becomes apparent that this simplified screen would perform much better if the following conditions prevailed: 1. Each particle is delivered individually to an aperture. 2. The particle arrives at the opening with zero forward velocity. 3. The particle traveled normal to the screen surface. 4. The smallest dimension of the particle was centered on the opening. 5. Screening surface has little or no thickness.
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
ELLIPTICAL STROKE FLAT SCREENS

The elliptical stroke flat screen combines the efficiency of a horizontal with the tumbling action of a circular stoke incline screen. Figure 1 illustrates how the elliptical stroke is achieved with the three shaft design. The result is a screen with a high stroke amplitude, and high g-force that resists plugging. The ability to change the angle of throw (timing angle), amplitude of throw (stroke length), and speed (RPM) of the screen allows the screen to be fine-tuned to maximize production. The bearing mounting method provides long service life due to the outer ring rotation, which distributes the loads over a larger area than conventional inner race rotation designs. The variations in the stroke patterns of Incline and Horizontal Screens are illustrated in Figure 1. The elliptical stroke JCI screen with a 34" stroke run at 875 RPM produces 8 Gs of acceleration to the vibrating basket. This aggressive vibration helps prevent damp sticky material from adhering to the wirecloth, reducing the effective opening. The stroke angle can be changed in 5 degree increments from 30 to 60 degrees of inclination. This feature allows the operator to change from a relatively flat angle that results in a relatively high material velocity across the screen, to more vertical angle that keeps the material on the screen longer to allow the fines and near size more time to find and pass through the screen opening. The operating speed of the JCI flat screen can be easily changed with the factory supplied adjustable speed sheave. The removable shims in the sheave effectively change the pitch diameter of the drive sheave to vary the screen speed from 740 rpm to 875 rpm. General guidelines for setting the operational parameters on the JCI flat screen are given in Figure 2. In general, coarse screening uses a large amplitude, slow speed, flat timing angle. As the Material to be screened becomes finer, the amplitude gets smaller, the speed is increased, and the timing angle is steeper for best results.
122
DAMP STICKY MATERIAL

The adjustment features of the JCI flat screen, speed, stroke, and timing angle, can effectively be used to maximize screen efficiency. Screen surface plugging and blinding reduces the open area of the screen media thereby severely reducing efficiency. In plugging, the apertures in the screening media are plugged by the wedging of particles in the openings, usually this happens when there is a large amount of near-size, material passing over the screen. In blinding, undersize particles adhere to the screen structure and then to each other until the aperture has closed completely. This condition usually arises when the material is fine, damp and surface moisture has caused it to become sticky. There are several solutions to the plugging blinding problem. The simplest is to adjust the speed, stroke length, and inclination angle of the vibrating screen. A vigorous motion with a large stroke lifts the near-size particles out of the openings and moves them along the surface of the screen media. The high g-force acceleration associated with the JCI flat screen accelerates the screen away from the material faster than gravity causes the material particles to free-fall. This action effectively prevents plugging that can affect the efficiency of short stroke horizontal screens. The aggressive vibration simultaneously shakes the clinging particles loose from the screen media and passes them on to the throughs material and minimize the blinding of the screen surface. The JCI flat screen allows the operator to adjust the speed, stroke length and stroke inclination to minimize the effect of plugging and blinding. If the material characteristics change, the operating parameters can be changed to optimize the screening efficiency with changing material characteristics. To augment the effectiveness of changing stroke size, rpm, and timing angle, the following can be done. 1. The use of Polyurethane deck material with flexible panels will help prevent material build-up. As material sticks to the panel the mass increases to a point were the sticky material crumbles and is flung off the screening media.
123
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
GUIDELINES FOR STROKE ADJUSTMENTS

Size of Material Coarse 114" Plus
Figure 2
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
Medium 3 4" - 114" Fine

3
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
Extra Fine 3 8" Minus
30 - 40
125
SPRAY PIPE DESIGN

AMOUNT OF WATER REQUIRED TO WASH ROCK
As a guideline use (5 to 10 gallons/minute) per (yard/hour) or for 100 pound per cubic foot rock. As a guideline use (3.7 to 7.4 gallons/minute) per (ton/hour). Example: (200 ton/hour) x (3.7 gallons/minute) per (ton/hour) = 740 gallons/minute
Nozzle Spray Pipe Dual Flat Spray Pattern Standard Orifice Size 1/4"
PIPES/DECK SCREEN MODEL TOP CTR BT
TOTAL PIPES PER SCREEN
TOTAL NOZZLES PER SCREEN
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
SPLASH SPRAY PIPES

Splash Spray Pipe Single Flat Splash Pattern 3/16" Diameter Holes on 2" Centers
Approximately the same capacity as Nozzle Spray Pipes Shown above.
126
NOTES:
127
JCI HORIZONTAL OVAL MOTION VIBRATING SCREENS

JCI Horizontal Screens are of a triple shaft design that provides a true oval vibrating motion, and feature a huck-bolted basket assembly, fully contained lubrication system, and rubber springs to reduce basket stress. Their low profile height makes them ideal for portability, and their adjustment capabilities of speed, stroke length, and stroke angle enable them to be well suited for both fine and coarse screening applications. JCI horizontal screens can be retrofitted with either wire cloth or urethane panels, and can be easily converted to wet screen applications. JCI Horizontal screens are available in several configurations in sizes ranging from 5x14 up to 8x20 in both two and three deck designs.
PATENT APPLIED FOR
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.
PATENT APPLIED FOR
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
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MEDIUM SCALPER SCREENS

The medium scalper screen is an excellent machine for coarse screening and light duty scalping applications, by implementing a slightly lower frequency and more aggressive stroke length as compared to the standard series. Medium scalper screens also feature a heavier duty construction for up to 14" feed.
PATENT APPLIED FOR
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
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HEAVY SCALPER SCREENS

The heavy scalper two-deck screens are designed for heavy duty scalping applications, by implementing the lowest frequency and most aggressive stroke length in the family of JCI horizontal screens. Heavy scalper screens also feature the heaviest duty construction that can accept up to 18" feed sizes.
PATENT APPLIED FOR
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
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LOW INCLINED SCREENS

For those producers who prefer the classic horizontal screen design, JCI also manufactures a full line of 212 inclined screens. Contact the factory for additional information on available sizes and models.
PATENT APPLIED FOR
SPECIAL SCREEN DESIGNS

JCI also provides several special designs including classic models for installation on Model 1145 and 1213 ElJay cone/screening plants, screens designed with additional clearance under the shaft tubes, and special versions featuring special sloped decks, step decks, split crown rails, etc. Contact the factory for additional information on all available models and sizes.
PATENT APPLIED FOR
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NOTES:
133
JCI INCLINED SCREENS

JCI incline screens feature HD side and reinforcing plates, huck bolted construction, an adjustable operating incline from 15-25 degrees, adjustable stroke amplitudes, AR lined feed boxes, and HD double-roll bronze cage spherical roller bearings. JCI incline screens are available in both single and dual shaft arrangements, two and three deck configurations, and are available in sizes ranging from 6x20 up to 8x20.
PATENT APPLIED FOR
JCI SINGLE SHAFT INCLINED SCREENS

JCI single shaft incline screens are well suited for stationary installations, for applications where the feed gradation to the screen is constant, or when a circular stroke pattern will provide the desired results. Incline screens also enable a lower bed depth of material due to an increased material travel speed. to minimize power consumption while maximizing access for maintenance Standard stroke length (Amplitude) . . . . . . . . . . . . . . 38" stroke Standard operating speed . . . . . . . . . . . . . . . . . . . . . . 800 rpm Optional stroke and speed relationships . . . . . . . . . . . Stroke (in.)
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
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JCI DUAL SHAFT INCLINED SCREENS

In addition to the benefits described of the single shaft incline designs, JCI dual shaft incline screens will provide increased bearing life as compared to a single shaft arrangement, due to the load being distributed over additional bearing surface. In some cases, dual shaft screens will also provide the benefit of a more aggressive screen action in applications where the feed end of the screen becomes top heavy with a high volume of material.
PATENT APPLIED FOR
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
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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
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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
PATENT APPLIED FOR
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
JCI VIBRATING SCREEN CAPACITY CALCULATIONS

Most manufacturers use a modified version of the VSMA (Vibrating Screen Manufactures Association) formula to determine screen capacity. The twelve factors used in the formula below are based in large part on the VSMA charts and formula. Formula: A=B*S*D*V*H*T*K*Y*P*O*W*F
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
JCI EXPLANATION OF PARAMETERS

A = Actual capacity B = Basic capacity
S = Incline factor
140
D = Deck factor
V = Over size factor
141
H = Half size factor
T = Slot factor
142
K = Material Condition factor
Y = Spray factor
143
P = Shape factor
O = Open Area factor
144
W = Weight factor
F = Efficiency factor
145
TYP = Type of Stroke Factor
146
STR = Stroke Length factor
147
TIM = Timing Angle Factor
148
RPM - Revolutions Per Mintue factor
149
NEA = Near Size factor

Chart A - Normal Material Distribution Curve
Chart B - Material Distribution Curve with Increased 2" Near Size
Chart C - Material Distribution Curve with Reduced 2" Near Size
150
NEA = Near Size factor
151
BED = Bed Depth factor

Where DM is the calculated Depth of Material in inches. TP is tons per hour of material going off the end of the deck, not just the oversized but also the carryover. KD is the density of material in cubic feet per ton. The formula for calculating material depth is shown below: DM + (TP * KD) / (5.0 * SP * WD)
SP = Conveying Speed factor

Chart A - Conveying Velocity at 20 Incline Incline Screen with Circular Stroke
152

Chart B - Conveying Velocity at 15 Incline Incline Screen with Circular Stroke
Chart C - Conveying Velocity at 10 Incline Incline Screen with Circular Stroke
153

Chart A - Conveying Velocity at 60 Timing Angle Flat Screens
154

Chart B - Conveying Velocity at 55 Timing Angle Flat Screens
Chart C - Conveying Velocity at 50 Timing Angle Flat Screens
155

Chart D - Conveying Velocity at 45 Timing Angle Flat Screens
Chart E - Conveying Velocity at 40 Timing Angle Flat Screens
156

Chart F - Conveying Velocity at 35 Timing Angle Flat Screens
Chart G - Conveying Velocity at 30 Timing Angle Flat Screens
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
KOLBERG *FACTORS FOR CALCULATING SCREEN AREA**

Formula: Screening Area =
*Basic Operating Conditions Feed to screening deck contains 25% oversize and 40% halfsize Feed is granular free-flowing material Material weighs 100 lbs. per cu. ft. Operating slope of screen is: Inclined Screen 18 - 20 with flow rotation Horizontal Screen 0 Objective Screening Efficiency95% **Furnished by VSMA U = STPH Passing Specified Aperture
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
FACTOR B (Percent of Oversize in Feed to Deck)

% Oversize Factor B % Oversize Factor B % Oversize Factor B 5 10 15 20 25 1.21 1.13 1.08 1.02 1.00 40 .88 75 .58 45 .84 80 .53 50 .79 85 .50 55 .75 90 .46 60 .70 95 .33 30 .96 65 .66 35 .92 70 .62
FACTOR C (Percent of Halfsize in Feed to Deck)

% Halfsize Factor C % Halfsize Factor C % Halfsize Factor C 0 .40 35 .90 5 .45 10 .50 15 .55 20 .60 25 .70 30 .80
8" 3 4" 5 8" 1 2" 3 8" 1 4" 3 16" 1 8" 3 32" 1 16" 1 32"
40 45 50 55 1.00 1.10 1.20 1.30
60 65 1.40 1.55
70 75 80 85 90 1.70 1.85 2.00 2.20 2.40
FACTOR D (Deck Location)

Top 1.00 Second .90 Third .80
FACTOR H (Shape of Surface Opening)

Square . . . . . . . . . . 1.00 Short Slot (3 to 4 times Width) . . . . 1.15 Long Slot (More than 4 Times Width) . 1.20
FACTOR E (Wet Screening)

Opening 132" 116" 18" 316" 14" 38" 12" 34" 1" Factor E 1.00 1.25 2.00 2.50 2.00 1.75 1.40 1.30 1.25
FACTOR F (Material Weight)

Lbs./cu.ft. 150 125 100 90 80 75 70 60 50 30 Factor F 1.50 1.25 1.00 .90 .80 .75 .70 .60 .50 .30
FACTOR J (Efficiency)
95% 90% 85% 80% 75% 70% . . . . . . . . . . . . 1.00 . . . . . . . . . . . . 1.15 . . . . . . . . . . . . 1.35 . . . . . . . . . . . . 1.50 . . . . . . . . . . . . 1.70 . . . . . . . . . . . . 1.90
FACTOR G (Screen Surface Open Area)

Factor G = % Open Area of Surface Being Used % Open Area Indicated in Capacity
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
Note: F = Fixed grizzly bars A = Adjustable grizzly bars
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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 271 shown)
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.
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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.
KOLBERG PORTABLE SCREENING PLANTS

Model 241 Sand & Gravel TPH Soil TPH Hopper Capacity Belt Feeder Feed Conveyor Up to 250 Up to 150 8 cu.yd. 30" x 11'-6" 24" x 40' Model 271 Up to 350 Up to 250 9 cu.yd. 36" x 11'-6" 30" x 40' 4' x 8', 2 deck 4' x 10', 2 deck 4' x 8', 3 deck n/a 80 HP Model 291 Up to 650 Up to 550 12 cu.yd. 42" x 12' 42" x 43' n/a Model 391 Up to 600 Up to 400 12 cu.yd. 42" x 14' 36" x 38' n/a
Std. Screen Size 4' x 6', 2 deck Optional Screen 4' x 8', 2 deck Size On-Board Conveyors Power n/a 62 HP
5' x 12', 2 deck 5' x 12', 2 deck
n/a 165 HP
three (3) 114 HP
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KOLBERG DIRECT SCREEN (KDS)

There are two different models of Kolberg direct feed screens. Models 708 KDS and 710 KDS. These plants are all hydraulic with Parker Seal-Lok, O-ring fittings and include self-contained diesel power units.
Screen Size Opening for the Loader Bucket Loader Bucket Cu. Yd. Landing Gear Optional Field Replaceable Conveyor
708 KDS 8'-0" x 6'-812" 10'-0" 1 to 3 Hydraulic
710 KDS 10'-0" x 6'-812" 12'-0" 3 to 5 Hydraulic 48" x 35' Fines Conveyor
N/A
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NOTES:
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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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CONVEYOR ELEVATION CHART

21
OR VEY N CO
80' 40' 50' 60'
' 120
50' 40' 30' 20' 10' 5'
' 100
12 9
40' 171
50'
60'
80'
100'
120'
150'
HORIZONTAL DISTANCE IN FEET
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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CONICAL STOCKPILE CAPACITY

Volume Tons (100 lbs. Cu. Yds. /cu. ft.) Volume Tons (100 lbs. Cu. Yds. /cu. ft.)
6 8 10 12 14 16 18 20 22 24
16 21 26 31 36 42 47 52 57 63
14 34 66 114 181 270 384 527 701 911
19 46 89 154 244 364 519 711 947 1229
26 28 30 35 40 45 50 55 60
68 73 78 91 104 117 130 143 156
1158 1446 1779 2824 4216 6003 8234 10960 14228
1563 1952 2401 3813 5691 8104 11116 14795 19208
LIVE STORAGE
"H" 37.5 37.5 "D" APPROX
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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APPROXIMATE VOLUME OF CIRCULAR STOCKPILE

V3 = V1 + V2 V3 = Total Volume of Stockpile - in cu. yds. V1 = Volume of Ends (Volume of Conical Stockpile) - in cu. yds. V2 = Volume of Stockpile for 1 Arc - in cu. yds. V2 = H2R 1187
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
VOLUME OF STOCKPILE SEGMENT FOR 1 ARC V2
V1 2
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V2 = Volume of Stockpile Segment for 1 degree Arc (cu. yds.)

Radius (in feet) 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150
Stockpile Height (H) in Feet
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
187.7 196.2 204.7 213.2 221.8 230.3 238.8 247.4 255.9
252.7 263.3 273.8 284.3 294.9 305.4 315.9
344.0 356.8 369.5 382.3
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
Feet 60 80 100 120 150
Feet 20.5 26.7 32.9 39.1 48.4
Feed 57 76 95 114 142.5
Cu. Yds. 567 1,254 2,346 3,938 7,469
Tons Cu. Yds. 766 20.2 1,693 45.6 3,167 86.6 5,316 146.8 10,083 281.2
Tons 27.3 61.6 116.9 198.2 379.6
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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CONVEYOR BELT CARRYING CAPACITY AT VARIOUS SPEEDS

Belt Width Inches 18 24 30 36 42 48 54 60 72 100 69 132 215 318 441 585 748 932 1360 150 103 198 322 477 661 877 1122 1398 2040 200 138 264 430 636 882 1170 1496 1864 2720 250 172 330 537 795 1102 1462 1870 2330 3400 Capacity in Tons Per Hour* Belt Speeds F.P.M. 300 350 400 207 396 645 954 1323 1755 2244 2796 4080 241 462 752 1113 1543 2047 2618 3262 4760 276 528 860 1272 1764 2340 2992 3728 5440 450 310 594 967 1431 1984 2632 3366 4194 6120 500 345 660 1075 1590 2205 2925 3740 4660 6800 550 379 726 1182 1749 2425 3217 4114 5126 7480 600 414 792 1290 1908 2646 3510 4488 5592 8160
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.
RECOMMENDED MAXIMUM BELT SPEEDS

Material being conveyed Grain or other free-flowing, nonabrasive material Belt Speeds (fpm) 500 700 800 1000 400 600 800 1000 350 500 600 350 Belt Width (inches) 18 24-30 36-42 48-96 18 24-36 42-60 72-96 18 24-36 Over 36 Any width
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
Any width Any width
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.
FACTORS AFFECTING THE CROSS SECTION ARE:

The angle of repose of a material is the angle that the surface of a normal, freely formed pile, makes to the horizontal. The angle of surcharge of a material is the angle to the horizontal that the surface of the material assumes while the material is at rest on a moving conveyor belt. This angle usually is 5 to 15 less than the angle of repose, though in some materials it may be as much as 20 less. The flowability of a material, as measured by its angle of repose and angle of surcharge, determines the cross-section of the material load that safely can be carried on a belt. It also is an index of the safe angle of incline of the belt conveyor. The flowability is determined by such material characteristics as: size and shape of the fine particles and lumps, roughness or smoothness of the surface of the material particles, proportion of fines and lumps present, and moisture content of material.
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FLOWABILITYANGLE OF SURCHARGE ANGLE OF REPOSE

Very free flowing 5 Angle of surcharge Free flowing 10 Angle of surcharge Average Flowing 20 Angle of 25 Angle of surcharge surcharge Sluggish 30 Angle of surcharge
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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FACTOR X - HORSEPOWER REQUIRED TO OPERATE EMPTY CONVEYOR AT 350 FPM

Conveyor Width 18" 24" 30" 36" 42" 48" Center-Center of Pulleys 25' 0.7 0.9 1.4 1.8 2.1 2.7 50' 0.8 1.1 1.6 2.0 2.5 2.8 75' 0.9 1.2 1.8 2.1 2.7 3.2 100' 1.1 1.4 1.9 2.6 3.0 3.4 150' 1.2 1.6 2.2 2.9 3.5 3.7 200' 1.3 1.8 2.5 3.1 3.7 4.2 250' 1.4 2.0 2.8 3.4 4.2 5.3 300' 1.7 2.1 3.0 3.8 4.6 5.6 350' 1.8 2.3 3.2 4.2 5.3 6.2 400' 2.0 2.5 3.5 4.4 6.0 6.7
FACTOR Y - ADDITIONAL HP REQUIRED TO OPERATE LOADED CONVEYOR ON THE LEVEL

TPH 100 150 200 250 300 350 400 500 600 700 800 900 1000 25' 0.5 0.8 1.0 1.3 1.5 1.8 2.0 2.5 3.0 3.5 4.0 4.5 5.0 50' 0.6 0.9 1.2 1.5 1.8 2.1 2.4 3.0 3.6 4.2 4.8 5.4 6.0 75' 0.7 1.0 1.3 1.6 2.0 2.3 2.6 3.3 3.9 4.6 5.2 5.9 6.5 Center-Center of Pulleys 100' 150' 200' 250' 0.8 0.9 1.0 1.1 1.1 1.3 1.5 1.7 1.5 1.7 2.0 2.2 1.9 2.1 2.5 2.8 2.3 2.6 3.0 3.3 2.6 3.0 3.5 3.9 3.0 3.4 4.0 4.4 3.8 4.3 5.0 5.5 4.5 5.1 6.0 6.6 5.3 6.0 7.0 7.7 6.0 6.8 8.0 8.8 6.8 7.7 9.0 9.9 7.5 8.5 10.0 11.0 300' 1.3 1.9 2.5 3.1 3.8 4.4 5.0 6.3 7.5 8.8 10.0 11.3 13.0 350' 1.4 2.1 2.8 3.5 4.2 4.9 5.6 7.0 8.4 9.8 11.2 12.6 14.0 400' 1.5 2.3 3.0 3.8 4.5 5.3 6.0 7.5 9.0 10.5 12.0 13.5 15.0
FACTOR Z - HORSEPOWER REQUIRED TO LIFT LOAD ON BELT CONVEYOR

TPH 100 150 200 250 300 350 400 500 600 700 800 900 1000 10' 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5.0 6.0 7.0 8.0 9.0 10.0 20' 2.0 3.0 4.0 5.0 6.0 7.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 30' 3.0 4.5 6.0 7.5 9.0 10.5 12.0 15.0 18.0 21.0 24.0 27.0 30.0 40' 4.0 6.0 8.0 10.0 12.0 14.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0 Lift 50' 5.0 7.5 10.0 12.5 15.0 17.5 20.0 25.0 30.0 35.0 40.0 45.0 50.0 60' 6.0 9.0 12.0 15.0 18.0 21.0 24.0 30.0 36.0 42.0 48.0 54.0 60.0 70' 7.0 10.5 14.0 17.5 21.0 24.5 28.0 35.0 42.0 49.0 56.0 63.0 70.0 80' 8.0 12.0 16.0 20.0 24.0 28.0 32.0 40.0 48.0 56.0 64.0 72.0 80.0 90' 100' 9.0 10.0 13.5 15.0 18.0 20.0 22.5 25.0 27.0 30.0 31.5 35.0 36.0 40.0 45.0 50.0 54.0 60.0 63.0 70.0 72.0 80.0 81.0 90.0 90.0 100.0
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HOW TO DETERMINE CONVEYOR BELT SPEED

Five (5) factors are required to determine conveyor belt speed. A = Motor RPM B = Motor Sheave Dia. (inches) C = Reducer Sheave Dia. (inches) D = Reducer Ratio E = Dia. of Pulley (inches) A x B C = Reducer Input Speed (RPM) Reducer Input Speed (RPM) D = Drive Pulley RPM Drive Pulley RPM x 0.2618 x E = Conveyor Belt Speed (FPM) Example: Determine Conveyor Belt Speed of a 30" x 60' conveyor with a 15 HP, 1750 RPM electric motor drive, 16" head pulley, 6.2" diameter motor sheave, 9.4" diameter reducer sheave and a 15:1 reducer. A = 1750 RPM B = 6.2 C = 9.4 D = 15 E = 16 1750 x 6.2 9.4 = 1154 RPM (Reducer Input) 1154 RPM 15 = 77 RPM (Pulley Speed) 77 RPM x 0.2618 x 16 = 322 FPM Conveyor Belt Speed NOTE: 1. To speed up the conveyor belt, a smaller reducer sheave could be used or a larger motor sheave could be used. 2. To slow down the conveyor belt, a larger reducer sheave could be used or a smaller motor sheave could be used.
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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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SIZE 24" x 40' 24" x 50' 30" x 50'
MOTOR hyd. hyd. hyd.
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.
183
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.
184
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
Other widths available upon request.
185
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
186
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
MODEL 33-30110 33-30130 33-30150 33-36130 33-36150
SIZE 30" x 110' 30" x 130' 30" x 150' 36" x 130' 36" x 150'
187
188
70'/130' TELESCOPING STACKER
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
Other belt widths and lengths available.
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
Other belt widths and lengths available.
189
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.
SPECIALTY CONVEYORS INCLUDE:

Series 40T: Transflite conveyors (also known as grasshopper conveyors) which are semi-mobile, overland transfer conveyors. Standard sizes are 24", 30", 36" belt widths x 60', 80', 100' lengths. May have a single axle near the discharge end or one skid type support. Transflite conveyors are easily moved around in the pit. Other sizes are available. Series 47S: Stackable conveyors. Made with a 24" overall height frame of channel iron and angle with the components recessed in the frame. Up to 8 conveyors can be stacked on one trailer for multiple unit transport. Standard sizes are 24", 30" and 36" belt widths x 50' or 60' lengths. Often used as transfer conveyors in portable crushing and screening spreads. Series 47SP: Portable 36" x 50' or 60' stackable conveyor with special hinged frame section and hold down wheels. Often used as under crusher discharge conveyor or under the discharge chutes of portable screening plants where clearance is minimal. Also known as Dogleg conveyors.
190
NOTES:
191
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.
192
(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.
193
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.
194
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
Example A Percent Passing 100 90 -100
Example B Percent Passing 100 96 -100
25 - 60
35 - 70 0 - 15
4" (19.0 mm) 2" (12.7 mm)
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
1 sack cement = 1 cu. ft.; 4 sacks = 1 bbl.; 1 bbl. = 376 lbs.
195
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
Solid Rock DensityLbs. Per Ft.3 (Approx.)

145 10 18 29 43 61 84 112 145 184 230 283 344 412 489 575 671 893 1160 1475 1842 2265 2749 3298 3914 4978 150 11 19 30 44 63 87 116 150 191 238 293 356 426 506 595 694 925 1200 1526 1905 2343 2844 3412 4050 5150 155 11 19 31 46 65 90 119 155 197 246 302 367 440 523 615 717 954 1239 1575 1967 2419 2936 3522 4180 5321 160 12 20 32 47 68 93 123 160 203 254 312 379 454 539 634 740 985 1279 1626 2031 2498 3031 3636 4316 5493 165 12 21 33 49 70 95 127 165 210 262 322 391 469 556 654 763 1016 1319 1677 2094 2576 3126 3750 4451 5664 170 12 21 34 50 72 98 131 170 216 270 332 403 483 573 674 786 1047 1359 1728 2158 2654 3221 3864 4586 5836 175 13 22 35 52 74 101 135 175 222 278 342 415 497 590 694 810 1078 1399 1779 2222 2732 3316 3978 4722 6008 180 13 23 36 53 76 104 139 180 229 286 351 426 511 607 714 833 1108 1439 1830 2285 2811 3411 4092 4857 6179 185 13 23 37 55 78 107 142 185 235 294 361 438 526 624 734 856 1139 1479 1881 2349 2889 3506 4206 4992 6351
NOTE: The above is given as general information only; each job will carry its individual specification.
196
MOTOR WIRING AT STANDARD SPEEDS

From National Electrical Code
Min. Full Size Size Load Wire ConAmp. AWG duit Per Rubber in Phase Covered Inches **Max. Min. Rating Full Size Size of Load Wire ConBranch Amp. AWG duit Circuit Per Rubber in Fuses Phase Covered Inches **Max Rating of Branch Circuit Fuses
HP.
Single-Phase Induction Motors

230 Volts 1 3.5 14 15 2 1 4.7 14 15 2 1 1 5.5 14 20 2 1 112 7.6 14 25 2 1 2 10 14 30 2 1 3 14 12 45 2 3 5 23 8 70 4 712 34 6 1 110 10 43 5 114 125 ,** Where high ambient temperature is present it may, in some cases, be necessary to install next larger size thermal overload relay.
1
2 3 4
7 9.4 11 15.2 20 28 46
120 Volts 1 14 2 1 14 2 1 14 2 1 12 2 3 10 4 3 8 4 4 114
25 30 35 45 60 90 150
3-Phase Squirrel-Cage Induction Motors

1 112 2 3 5 712 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 230 Volts 1 3.3 14 2 1 4.7 14 2 1 6 14 2 1 9 14 2 1 15 12 2 3 22 8 4 3 27 8 4 38 6 114 52 4 114 64 3 114 77 1 112 101 00 2 125 000 2 149 200,000 C.M. 212 180 0000 212 245 500 3 310 750 312 360 1000 4 480 580 696 * 15 * 15 * 20 * 30 * 45 60 70 80 110 150 175 200 250 300 300 500 500 600 1.7 2.4 3.0 4.5 7.5 11 14 19 26 32 39 51 63 75 90 123 155 180 240 290 348 460 Volts 1 14 2 1 14 2 1 14 2 1 14 2 1 14 2 1 14 2 1 12 2 3 10 4 3 8 4 6 114 6 114 4 114 3 114 1 0 000 0000 300 500 112 2 2 212 212 3 * 15 * 15 * 15 * 15 * 25 30 35 50 70 70 80 100 125 150 200 250 350 400 500
197
MOTOR WIRING AT STANDARD SPEEDS, (Continued)

From National Electrical Code
Min. Full Size Size Load Wire ConAmp. AWG duit Per Rubber in Phase Covered Inches 115 Volts 1 14 2 1 12 2 3 10 4 3 8 4 6 1 3 114 1 112 00 2 000 2 300 212 400 3 700 312 1000 4 **Max. Min. Rating Full Size Size of Load Wire ConBranch Amp. AWG duit Circuit Per Rubber in Fuses Phase Covered Inches 230 Volts 1 14 2 1 14 2 1 14 2 1 12 2 3 10 4 6 1 6 1 4 114 1 112 0 2 00 2 0000 212 300 212 400 3 600 312 1000 4 **Max Rating of Branch Circuit Fuses
HP.
DIRECT CURRENT MOTORS

1 112 2 3 5 712 10 15 20 25 30 40 50 60 75 100 8.4 12.5 16.1 23 40 58 75 112 140 184 220 292 360 15 20 25 35 60 90 125 175 225 300 350 450 600 4.2 6.3 8.3 12.3 19.8 28.7 38 56 74 92 110 146 180 215 268 355 15 15 15 20 30 45 60 90 125 150 175 225 300 350 450 600
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.
NEMA Frame Numbers for Polyphase Induction Motors

T Frame Horsepower 2 3 5 712 10 15 20 25 30 40 50 60 75 1800 RPM 145T 182T 184T 213T 215T 254T 256T 284T 286T 324T 326R 364T 365T 1200 RPM 184T 213T 215T 254T 256T 284T 286T 324T 326T 364T 365T 404T 405T
198
DIMENSIONS, IN INCHES, OF ELECTRIC MOTORS

By NEMA Frame Number
M+N 182T 184T 213 213T 215 215T 254T 254U 256T 256U 284T 284U 286T 286U 324T 324U 326T 326U 364T 364U 365T 365U 404T 404U 405T 405U 444U 445U 734 814 914 958 10 1038 1238 12 8
1
D 412 412 514 514 514 514 614 6 4

1
E 334 334 414 414 414 414 5 5 5 5 512 512 512 5 2

1 1
F 214 234 234 234 312 312 418 4 8

1
U 118 118 118 138 118 138 158 1 8

3
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
1314 13 1418 1438 1478 15 8

1 3
614 614 7 7 7 7 8 8 8 8 9 9 9 9 10 10 10 10 11 11
5 5 434 434 512 5 2

1 1
158 138 178 158 178 1 8

5
15 4 1618 1612 1678 1738 17 8

7 7
6 4 614 614 614 7 7 7 7 8 8 8 8 9 9
5 4 514 6 6 558 5 8
5
2 8
1
178 218 178 238 2 8

1
17 8 1838 20 1978 2034 2058 2338 24 8

3
6 8
1
2 8
3
618 618 618 678 678 714 8 4

1
218 278 238 278 238 278 2 8

7
4 x 18 4 x 18 1 x 1 4 8 5 16 x 532 1 x 1 4 8 5 16 x 532 3 x 3 8 16 5 16 x 532 3 x 3 8 16 5 16 x 532 1 x 1 2 4 3 8 x 316 1 x 1 2 4 3 x 3 8 16 1 x 1 2 4 1 x 1 2 4 1 x 1 2 4 1 x 1 2 4 5 x 5 8 16 1 x 1 2 4 5 x 5 8 16 1 x 1 2 4 3 x 3 4 8 5 x 5 8 16 3 x 3 4 8 5 x 5 8 16 3 x 3 4 8 3 x 3 4 8

1 1
199
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
.640 .605 .530 .405 .390
.690 .640 .560 .430 .405
.750 .670 .605 .485 .435
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.
GENERATOR SIZE TO POWER ELECTRIC MOTORS ON CRUSHING AND SCREENING PLANTS

The minimum generator size to power a group of motors should be selected on the basis of the following rules which allow all motors to operate simultaneously with complete freedom of starting sequence. A. GENERATOR KW0.8 x total electric name plate horsepower. B. GENERATOR KW2 x name plate horsepower of the largest electric motor with across-the-line starter. C. GENERATOR KW1.5 x name plate horsepower of the largest electric motor with reduced voltage starting (with 80 percent starting voltage). D. GENERATOR KW2.25 x name plate horsepower of the largest electric motor with part winding starting. For across-the-line starting, use the larger of the two values determined from A and B. For reduced voltage starting, use the larger of the two values determined from A and C. For part winding starting, use the larger of the two values determined from A and D. For combinations of the above starting types, use the largest value determined from A, B, C, and D as they apply.
201
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
202
VELOCITY OF FLOW IN PIPES

3 4000 3000 2500 8" 2000 1500 6" 1000 900 800 700 U.S. GALLONS PER MINUTE 600 500 400 300 3" 4" 1000 900 800 700 600 500 400 300 U.S. GALLONS PER MINUTE 2000 1500 4 5 6 7 VELOCITY - FEET PER SECOND 8 9 10 11 12 12" 10" 13 14 15 16 17 4000 3000 2500
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
1" STD PIPE SIZE 8 9 10 11 12 VELOCITY - FEET PER SECOND 13 14 15 16 17
40 30 25 20
NOTE: Based on following IDs for Std. Wt. W:I or Steel Pipe
1" . . . . . 1.049" 114" . . . . 1.380" 112" . . . . 1.610" 2" . . . . . 2.067"
212" . . . . 2.469" 3". . . . . . 3.068" 4". . . . . . 4.026" 5". . . . . . 5.047"
6" . . . . . 6.065" 8" . . . . . 7.981" 10" . . . 10.020" 12" . . . 11.938"
203
FRICTION LOSS IN PIPES

.1 5000 4000 3000 2000 1000 1000 800 700 600 500 400 300 200 100 100 80 70 60 50 40 30 20
1-1 4" " 12 10 "
.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
U.S. GALLONS PER MINUTE
8"
6" 5"
300 200 100 100

3" 2-1 /2" 2" /2" /4 1-1 " 1"
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
NOTE: Based on new, Standard Weight Wrought Iron or Steel Pipe.
204
U.S. GALLONS PER MINUTE
FLOW OVER WEIRS

Settling Tanks, Classifiers, Sand Preps, Flumes
Settling Tanks, Classifiers, Sand Preps, Flumes
5 25 50 GPM OVERFLOW PER FOOT OF WEIR 75 100 150 200 250 300 400 5
OVERFLOW DEPTH (H) IN INCHES
25
50
75 100 150 200 250 GPM OVERFLOW PER FOOT OF WEIR
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.
205
OVERFLOW DEPTH (H) IN INCHES
SPRAY NOZZLES FOR VIBRATING SCREENS

The introduction of water under pressure over the vibrating screens often greatly improves screening efficiency as well as aiding in the removal of deleterious materials on the individual aggregate particles. KOLBERG utilizes Type WF Flat Spray Nozzles over the screens to produce a uniform, flat spray pattern without hard edges at pressures of 5 psi and up. Tapered edges of the spray pattern permits pattern overlap with even distribution of the spray. The impact of spray is generally greater with narrower spray angles, assuming the same flow rate.
AVAILABLE SPRAY ANGLES

Nozzle Size 0 15 25 40 50 65 80 90 All sizes All sizes thru WF 150 All sizes thru WF 150 All sizes thru WF 150 All sizes thru WR 200 All sizes All sizes All sizes thru WF 250
206
TYPE WF CAPACITY CHART

Nozzle NumberCapacity at 40 PSI
NOZZLE Equiv. NUMBER Orif. Male No. Dia. PIPE SIZE
1
40
60
80
100
CAPACITY GPM AT PSI PRESSURE 150 200 300 400 500
600
700
800
1000
WFM WFM WFM WFM WFM WFM WFM WFM WFM WFM WFM
2 4 4.5 5 5.5 6 6 7 8 8.5 9
.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
.28 .57 .64 .71 .78 .85
.32 .63 .71 .79 .87 .95
.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
SHADED COLUMNS INDICATE MOST AVAILABLE SIZES.
207
208
NOZZLE Equiv. NUMBER Orif. Male No. Dia.
1
TYPE WF CAPACITY CHARTNozzle NumberCapacity at 40 PSI

PIPE SIZE
10
15
20
30
CAPACITY GPM AT PSI PRESSURE 40 60 80 100 150
200
300
400
500
WFM* 15 WFM WFM WFM WFM WFM WFM 20 30 40 50 60 80
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
2.9 3.9 5.8 7.7
3.4 4.5 6.7 9.0
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
77.4 89.5 110.0 127.0 141.0
SHADED COLUMNS INDICATE MOST AVAILABLE SIZES.
DIMENSIONS AND WEIGHTS FOR TYPE WF

DIMENSIONS (Inches) PIPE SIZE
1 1 3 1 3
TYPE WFM WFM WFM WFM WFM
A
11 31
B
7 9
C
5
WEIGHT (Ounces) .4 .7 1.1 2.5 5.0
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
WATER VOLUME REQUIRED FOR WASHING AGGREGATES

The amount of water required for washing aggregates under average conditions is 3 to 5 GPM of water for each TPH of material fed to a washing screen. The finer the feed gradation, the more GPM of water required.
GETTING MAXIMUM WASHED PRODUCT FROM A VIBRATING SCREEN

Screen efficiency can be greatly increased by applying water directly to the feed box located ahead of the vibrating screen. Water volume applied must be sufficient to form a slurry in the feed box so that effective screening begins immediately when the wet product contacts the screen.
209
WEIGHTS AND MEASURESUNITED STATES Linear Measure
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
{
{ {
1 rod 1 yard 1 foot
= = =
4 rods 22 yards 66 feet 100 links 5.5 yards 16.5 feet 3 feet 36 inches 12 inches
Gunters or Surveyors Chain Measure

1 link = 7.92 inches 1 statute mile = 80 chains 1 chain =
100 links 4 rods 66 feet 22 yards
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
1 sq. rod 1 sq. yard 1 sq. foot
= = =
272 sq. feet { 30 sq. yards 1,296 sq. inches { 9 sq. feet
1 4 1 4
144 sq. inches
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
Troy Weight (For Gold and Silver)

1 pound = 12 ounces { 5760 grains 1 ounce = 20 pennyweights { 480 grains
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
1 hogshead 1 barrel 1 cu. ft. water
= = =
63 gallons 311/2 gallons 7.48 U.S. gals. 1728 cu. in. 6212 lbs. @ 62F
210
WEIGHTS AND MEASURESUNITED STATES Dry Measure

(When necessary to distinguish the dry pint or quart from the liquid pint or quart, the word dry should be used in combination with the name or abbreviation of the dry unit.)
1 quart (qt.) 1 peck (pk.) = = pints (pt.) {2 67.20 cu. in. 1 bushel (bu. ) =
{
= = =
8 quarts 16 pints 537.605 cu. in.
4 pecks 32 quarts 2150.42 cu. in.
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
7 cable lengths = {5,280 feet
Measures of Power
1 BTU per minute =
{
{
1 ft. lb. 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.
WEIGHTS AND MEASURESMETRIC Area Measure

1 sq. centimeter = (cm2) 1 sq. meter (m ) = {
2
100 sq. millimeters (mm2) 1,000,000 mm2 10,000 cm2
1 are (a) 1 hectare (ha) 1 sq. kilometer (km2)
100 m2
2
10,000 m = { 100 a = 1,000,000 m {100 ha
Linear Measure
1 centimeter (cm)=
1 decimeter (dm) = 1 meter (m)
{ = { { = {
10 millimeters (mm) 100 mm 10 cm 1,000 mm 10 dm
1 dekameter (dkm) 1 hectometer (hm) 1 kilometer (km)
= = =
10 m m { 100 10 dkm 1,000 m { 10 hm
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
1 decigram (dg) = 1 gram (g)
211
WEIGHTS AND MEASURESMETRIC (Continued) Cubic Measure

1 cubic centimeter (cm3) 1 cubic decimeter (dm3) = =
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
1 cubic meter (m3)
Volume Measure
1 centiliter (cl) 1 deciliter (dl) 1 liter* (l) = =
{ = {
10 milliliters (ml) 100 ml 10 cl 1,000 ml 10 dl
1 dekaliter (dkl) = 1 hectoliter (hl) 1 kiloliter (kl) =
{ = {
10 l 100 l 10 dkl 1,000 l 10 hl
*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 =
.986 U.S. horsepower 736 watts .736 kilowatts
32,550 ft. lbs. per min. 41.8 BTU per min.
METRIC-U.S. CONVERSION FACTORS

(Based on National Bureau of Standards) Area
Sq. cm. Sq. m. Ares Sq. m Hectare Sq. km x 0.1550 x 10.7639 x 1076.39 x 1.1960 x 2.4710 x 0.3861 = sq. ins. = sq. ft. = sq. ft. = sq. yds. = acres = sq. miles Sq. ins. Sq. ft. Sq. ft. Sq. yds. Acre Sq. miles x 6.4516 x 0.0929 x 0.00093 x 0.8361 x 0.4047 x 2.5900 = sq. cm = sq. m = ares = sq. m = hectares = sq. km
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
METRIC-U.S. CONVERSION FACTORS (Continued) Pressure (Continued)

Tons (long) per sq. ft. Kgs per sq. mm Tons (long) per sq. in. Kgs per cu. m Lbs. per cu. ft Kgs per m Lbs. per ft. Kg/m Ft. lbs. Kgs per sq. com Normal atmosphere x 10940.0 x .634973 x 1.57494 x .062428 x 16.0184 x .671972 x 1.48816 x 7.233 x .13826 x 0.9678 x 1.0332 = kg per sq. m = tons (long) per sq. in. = kg per sq. mm = lbs. per cu. ft. = kgs per cu. m = lbs. per ft. = kgs per m = ft. lbs. = kg/m = normal atmosphere = kgs per sq cm
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.
Miscellaneous Conversion Factors

Board feet x 144 sq. in. x 1 in. = cubic inches Board feet x .0833 = cubic feet Cubic feet x 6.22905 = gallons, Br. Imp. 2 = tons, Br. shipping Cubic feet x 2.38095 x 10Cubic feet x .025 = tons, U.S. shipping Degrees, angular x .0174533 = radians Degrees, F. (less 32F) x .5556 = degrees, Centigrade Degrees, centigrade x 1.8 plus 32 = degrees, F. Gallons, Br. Imp. x .160538 = cubic feet Gallons, Br. Imp. x 4.54596 = liters Gallons, U.S. x .13368 = cubic feet Gallons, U.S. x 3.78543 = liters Liters x .219975 = gallons, Br. Imp. Miles, statute x .8684 = miles, nautical Miles, nautical x 1.1516 = miles, statute Radians x 57.29578 = degrees, angular Tons, long x 1.120 = tons, short Tons, short x .892857 = tons, long Tons, Br. shipping x 42.00 = cubic feet Tons, Br. shipping x .952381 = tons, U.S. shipping Tons, U.S. shipping x 40.00 = cubic feet Tons, U.S. shipping x 1.050 = tons, Br. shipping Note: Br. Imp = British Imperial
213
APPROXIMATE WEIGHT OF MATERIALS

MATERIAL Andesite, Solid . . . . . . . . . . . . . . . . . . . . . . . Ashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basalt, Broken . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caliche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cement, Portland . . . . . . . . . . . . . . . . . . . . . Mortar, Portland, 1:212 . . . . . . . . . . . . . . . . Cinders, Blast Furnace. . . . . . . . . . . . . . . . . . Coal, Ashes and Clinkers. . . . . . . . . . . . . . . Clay, Dry Excavated. . . . . . . . . . . . . . . . . . . . Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . Dry Lumps . . . . . . . . . . . . . . . . . . . . . . . . . Wet Lumps . . . . . . . . . . . . . . . . . . . . . . . . . Compact, Natural Bed . . . . . . . . . . . . . . . . . Clay and Gravel, Dry . . . . . . . . . . . . . . . . . . . Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concrete, Asphaltic . . . . . . . . . . . . . . . . . . . . Gravel or Conglomerate . . . . . . . . . . . . . . . Limestone with Portland Cement . . . . . . . . Coal, Anthracite, Natural Bed. . . . . . . . . . . . . Broken. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bituminous, Natural Bed . . . . . . . . . . . . . . . Broken. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cullett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dolomite, Broken . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Earth, Loam, Dry Excavated . . . . . . . . . . . . . Moist Excavated . . . . . . . . . . . . . . . . . . . . . Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . Dense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft Loose Mud. . . . . . . . . . . . . . . . . . . . . . Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gneiss, Broken . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Granite, Broken or Crushed. . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravel, Loose, Dry. . . . . . . . . . . . . . . . . . . . . Pit Run, (Gravelled Sand) . . . . . . . . . . . . . . 1 Dry 4 - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . Wet 12 - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . Gravel, Sand & Clay, Stabilized, Loose . . . . . Compacted . . . . . . . . . . . . . . . . . . . . . . . . . Gypsum, Broken . . . . . . . . . . . . . . . . . . . . . . Crushed. . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Halite (Rock Salt) Broken . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hematite, Broken. . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limonite, Broken. . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limestone, Broken or Crushed . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetite, Broken . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marble, Broken . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marble Wet Excavated . . . . . . . . . . . . . . . . . . Mica, Broken . . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight, lbs./ft3 173 41 122 188 90 100 135 57 40 68 114 67 100 109 100 114 140 150 148 94 69 84 52 80-100 109 181 78 90 100 125 108 95 116 179 103 168 95 120 105 125 100 150 113 100 174 94 145 201 306 154 237 97 163 205 315 98 160 140 100 180 Weight, lbs./yd3 4,660 1,100 3,300 5,076 2,430 2,700 3,654 1,539 1,080 1,847 3,080 1,822 2,700 2,943 2,700 3,085 3,780 4,050 3,996 2,546 1,857 2,268 1,413 2,160-2,700 2,940 4,887 2,100 2,430 2,700 3,375 2,196 2,565 3,141 4,833 2,778 4,525 2,565 3,240 2,835 3,375 2,700 4,050 3,054 2,700 4,698 2,545 3,915 5,430 8,262 4,159 6,399 2,625 4,400 5,528 8,505 2,650 4,308 3,780 2,700 4,860 Weight, kg./m3 2,771 657 1954 3012 1442 1602 2162 913 641 1089 1826 1073 1602 1746 1602 1826 2243 2403 2371 1506 1105 1346 833 1281-1602 1746 2809 1249 1442 1602 2002 1730 1522 1858 2,867 1650 2691 1522 1922 1682 2002 1602 2403 1810 1602 2787 1506 2323 3220 4902 2467 3028 1554 2611 3,284 5046 1570 2563 2243 1602 2883
214
APPROXIMATE WEIGHT OF MATERIALS

MATERIAL Mud, Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Close . . . . . . . . . . . . . . . . . . . . . . . . . . Peat, Dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phosphate Rock, Broken . . . . . . . . . . . . . . . . Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Porphyry, Broken . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sandstone, Broken . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sand, Dry Loose . . . . . . . . . . . . . . . . . . . . . . Slightly Damp . . . . . . . . . . . . . . . . . . . . . . . Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet Packed . . . . . . . . . . . . . . . . . . . . . . . . . Sand and Gravel, Dry . . . . . . . . . . . . . . . . . . Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shale, Broken . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slag, Broken . . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slag, Screenings . . . . . . . . . . . . . . . . . . . . . . Slag, Crushed (34") . . . . . . . . . . . . . . . . . . . . Slag, Furnace, Granulated . . . . . . . . . . . . . . . Slate, Broken. . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stone, Crushed . . . . . . . . . . . . . . . . . . . . . . . Taconite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Talc, Broken . . . . . . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trap Rock, Broken. . . . . . . . . . . . . . . . . . . . . Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight, lbs./ft3 108 119 80-110 25 50 70 110 71.7 53 103 159 94 145 100 120 130 130 108 125 99 167 110 132 92 74 60 104 168 100 150-200 109 168 71.6 109 180 Weight, lbs./yd3 2,916 3,200 2,160-32,970 675 1,350 1,890 2,970 1,936 1,431 2,790 4,293 2,550 3,915 2,700 3,240 3,500 3,510 2,916 3,375 2,665 4,500 2,970 3,564 2495 1,998 1,620 2,800 4,535 2,700 4,050-5,400 2,931 4,535 1,936 2,950 4,870 Weight, kg./m3 1730 1906 1282-1762 400 801 1121 1762 1148 848 1650 2547 1506 2323 1602 1922 2082 2082 1730 2022 1586 2675 1762 2114 1474 1185 961 1666 2,691 1602 2403-3204 1746 2691 1148 1746 2883
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
Material Trap Rock Granite and Limestone
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
Granulated Slag Gravel Sand

NOTE:
1770 1640 3120 2900
1510 1390 2680 2450
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
DECIMAL EQUIVALENTS OF FRACTIONS

Inch
1 1
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
AREA AND CIRCUMFERENCE OF CIRCLES (INCHES)

Dia.
1 1
Area 0.0123 0.0491
Cir. .3926 .7854
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
8.295 10.21 9.621 10.99 12.566 12.56
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
512 23.758 17.27 612 33.183 20.42
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
THEORETICAL WEIGHTS OF STEEL PLATES

Size (Inches)
3 16 1 4 5 16 3 8 7 16 1 2
Wt. per Sq. Ft. (Lbs.)
Size (Inches)
Size (Inches)
7.65 10.20 12.75 15.30 17.85 20.40
9/16 5/8 3/4 7/8 1 11/8
22.95 25.50 30.60 35.70 40.80 45.90
114 138 112 158 134 2
51.00 56.10 61.20 66.30 71.40 81.60
STANDARD STEEL SHEET GAUGES & WEIGHTS

Size (Inches) Wt. per Sq. Ft. (Lbs.) Size (Inches) Wt. per Sq. Ft. (Lbs.) Size (Inches) Wt. per Sq. Ft. (Lbs.)
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
APPROXIMATE WEIGHTS PER LINEAL FOOT IN POUNDS OF STANDARD STEEL BARS

Dia. In. Rd. .101 .023 .042 .065 .094 .128 .167 .211 .261 .316 .376 .441 .511 .587 .667 .754 .845 .941 1.04 1.15 1.26 1.38 1.50 1.63 1.76 Hex. .012 .026 .046 .072 .104 .141 .184 .233 .288 .348 .414 .486 .564 .647 .736 .831 .932 1.03 1.15 1.27 1.39 1.52 1.66 1.80 1.94 Sq. .013 .030 .053 .083 .120 .163 .212 .269 .332 .402 .478 .561 .651 .747 .850 .960 1.08 1.20 1.33 1.46 1.61 1.76 1.91 2.08 2.24 Dia. In.
27 7
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
WEIGHTS OF FLAT BARS AND PLATES

To find weight per foot of flat steel, multiply width in inches by figure listed below:
Thickness Thickness
7 8 15
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
APPROXIMATE WEIGHT OF VARIOUS METALS

To find weight of various metals, multiply contents in cubic inches by the number shown; result will be approximate weight in pounds.
Iron. . . . . . . . . . . . . . . . . . . .27777 Steel . . . . . . . . . . . . . . . . . . .28332 Copper . . . . . . . . . . . . . . . . .32118 Brass . . . . . . . . . . . . . . . . . .31120 Lead . . . . . . . . . . . . . . . . . . .41015 Zinc . . . . . . . . . . . . . . . . . . .25318 Tin . . . . . . . . . . . . . . . . . . . .26562 Aluminum. . . . . . . . . . . . . . .09375
221
STEEL WIRE GAUGE DATA

Birmingham Wire Gauge or Stubs Gauge Thickness *Wt. per Inches Sq. Ft. Brown & Sharpe or American Wire Steel Wire Gauge (Washburn & Moren)
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
ROCKWELL-BRINELL CONVERSION TABLE

Brinell Numbers 10 mm Ball 3000 kg Load 690 673 658 645 628 614 600 587 573 560 547 534 522 509 496 484 472 460 448 437 426 415 404 Rockwell C Scale Brale Penetrator 150 kg Load 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 Brinell Numbers 10 mm Ball 3000 kg Load 393 382 372 362 352 342 333 322 313 305 296 290 283 276 272 265 260 255 248 245 240 235 230 Rockwell C Scale Brale Penetrator 150 kg Load 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20
AMERICAN STANDARD COARSE AND FINE THREAD SERIES

Size 0 1 2 3 4 5 6 8 10 12
5
Threads per inch Coarse Fine NC NF 64 56 48 40 40 32 32 24 24 20 18 16 14 13 80 72 64 56 48 44 40 36 32 28 28 24 24 20 20
Size
9 16 5 8 3 4 7 8
Threads per inch Coarse Fine NC NF 12 11 10 9 8 7 7 6 6 5 412 412 4 4 4 18 18 16 14 14 12
1 118 114 138 112 134 2 214 212 234 3 Over 3
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
Number of Teeth in Driven Gear & Sprocket
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
75 0.25 0.28 0.31 0.33 0.36
GENERAL INFORMATION ON CHAINS

The chain drive has three elements; the driver sprocket, the driven sprocket, and the endless chain which transmits power form the first to the second. The distance from center to center of adjacent chain pins is the chain pitch and also the sprocket pitch. Chain speed, f.p.m. = H.P. of drive = No. of teeth in sprocket x chain pitch (in.) x r.p.m. 12 Chain speed in f.p.m. x pull in pounds 33,000
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
CONVERSION OF THERMOMETER SCALE

Centigrade Fahrenheit C. = 5/9 (F.32) F. = 9/5 C. = 32 C. F. -80 -112. -70 -94. -60 -76. -50 -58.0 -45 -49.1 -40 -40.0 -35 -31.0 -30 -22.0 -25 -13.0 -20 -4.0 -19 -2.2 -18 -.4 -17 1.4 -16 3.2 -15 5.0 -14 6.8 -13 8.6 -12 10.4 -11 12.2 -10 14.0 -9 15.8 -8 17.6 -7 19.4 -6 21.2 -5 23.0 -4 24.8 -3 26.6 -2 28.4 -1 30.2 0 32.0 C. 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 F. 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 C. 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 F. 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 114.8 116.0 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 C. 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 F. 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 C. 91 92 93 94 95 96 97 98 99 100 105 110 115 120 130 140 150 160 170 180 190 200 250 300 350 400 500 600 700 800 900 1000 F. 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221. 230. 239. 248. 266. 284. 302. 320. 338. 356. 374. 392. 482. 572. 662. 752. 932. 1112. 1292. 1472. 1652. 1832.
MISCELLANEOUS USEFUL INFORMATION

To find capacity in U.S. gallons of rectangular tanks multiply length by width by depth (all in inches) and divide result by 231. To find number of U.S. gallons in pipe or cylinder, divide cubic contents in inches by 231. Doubling the diameter of a pipe increases its capacity four times. To find pressure in pounds per square inch of column of water, multiply height of column in feet by .434; to find height of column of water when pressure in pounds per square inch is known, multiply pressure in pounds by 2.309 (2.309 Feet Water exerts pressure on one pound per square inch.)
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
Lbs. kg Lbs. kg 5,660 2563 4,600 2086
Lbs. kg 3,250 1474 6,600 2994
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
*Ton = 2,000 lbs.
Courtesy Macwhyte Company
226
AVERAGE SAFE CONCENTRATED LOADS ON WOODEN BEAMSAVERAGE CONDITIONS
Span
Beam Dimension Width Depth In. 6 8 10 mm 152 203 254
Load
Ft. 4
meters 1.219
In. 6 8 8
mm 152 203 203
Lbs.
kg
2,100 952.6 4,970 2254 7,765 3522
1.829
6 6 8 8 10 10 12
152 152 203 203 254 254 305
6 8 8 10 10 12 12
152 203 203 254 254 305
1,398 634.1 2,490 1129 3,320 1506 5,184 2351 6,480 2939 9,330 4232
305 11,197 5097
2.438
6 6 8 8 10 10 12
152 152 203 203 254 254 305

1
6 8 8 10 10 12 12
152 203 203 254 254 305 305
1,050 476.3 1,866 846.4 2,488 1128 3,888 1763 4,860 2204 7,000 3175 8,400 3810
Concentrated Load = 2 of uniformly distributed load. 227
Under ideal conditions the load can be increased 13
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
NOTE: Formula used for w = __ calculation is as follows:

3
( )( )( )
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
Data From The Asphalt Institute
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
APPROXIMATE CUBIC YARDS OF CONCRETE IN SLABS OF VARIOUS AREAS AND THICKNESS

Area (Square Feet) 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 THICKNESS OF SLABS (Inches) 1.0 .03 .06 .09 .12 .15 .19 .22 .25 .28 .31 .62 .93 1.23 1.54 1.85 2.16 2.47 2.78 3.09 1.5 .05 .09 .14 .19 .23 .28 .32 .37 .42 .46 .93 1.39 1.83 2.32 2.78 3.24 3.70 4.17 4.63 2.0 .06 .12 .19 .25 .31 .37 .43 .49 .56 .62 1.23 1.85 2.47 3.09 3.70 4.32 4.94 5.56 6.17 2.5 .08 .16 .23 .31 .39 .46 .54 .62 .70 .78 1.54 2.32 3.10 3.86 4.63 5.40 6.20 6.95 7.72 3.0 .09 .19 .28 .37 .46 .56 .65 .74 .84 .93 1.85 2.78 3.70 4.63 5.56 6.48 7.41 8.33 9.26 3.5 .11 ,22 .33 .43 .54 .65 .76 .87 .97 1.08 2.16 3.24 4.32 5.40 6.48 7.56 8.64 9.72 10.80 4.0 .13 .25 .37 .50 .62 .74 .87 1.00 1.11 1.24 2.47 3.70 4.94 6.17 7.41 8.64 9.88 11.11 12.35 4.5 .14 .28 .42 .56 .70 .83 .97 1.11 1.25 1.39 2.78 4.17 5.56 7.00 8.33 9.72 11.11 12.50 13.89 5.0 .15 .31 .46 .62 .77 .93 1.08 1.24 1.39 1.55 3.09 4.63 6.17 7.72 9.26 10.80 12.35 13.89 15.43 5.5 .17 .34 .41 .68 .85 1.02 1.19 1.36 1.53 1.70 3.40 5.10 6.79 8.49 10.19 11.88 13.58 15.28 16.98 6.0 .19 .37 .56 .74 .93 1.11 1.30 1.67 1.67 1.85 3.70 5.56 7.41 9.26 11.11 12.96 14.82 16.67 18.52
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
DEFINITIONS AND TERMS

AdmixturesSubstances, not normally a part of paving materials or mixtures, added to them to modify their properties. AgglomerationGathering into a ball or mass. AggregatesIn the case of materials for construction, essentially inert materials which when bound together into a conglomerated mass by a matrix form asphalt, concrete, mortar or plaster; crushed rock or gravel screened to size for use on road surfaces. BallastBroken stone or gravel used in stabilizing a road bed or making concrete. Bank GravelGravel found in natural deposits, usually more or less intermixed with fine material, such as sand or clay, or combinations thereof; gravelly clay, gravelly sand clayey gravel and sandy gravel, indicate the varying proportions of the materials in the mixture. BaseFoundation for pavement. BeneficiationImprovement of the chemical or physical properties of a material or intermediate product by the removal of undesirable components or impurities. Binder CourseThe course, in sheet asphalt and bituminous concrete pavements, placed between base and surface courses. Binder SoilMaterial consisting primarily of fine soil particles (fine sand, silt, true clay and colloids); good binding properties; commonly referred to as clay binder. BleedingUpward migration of bituminous material resulting in film of bitumen on surface. Blow-upLocalized buckling or shattering of rigid pavement caused by excessive longitudinal pressure. BogWet spongy ground sometimes filled with decayed vegetable matter. BouldersDetrital material greater than about 8" in diameter. Construction JointVertical or notched plane of separation in pavement.
232
DEFINITIONS AND TERMS (Continued)

Contraction JointJoint of either full depth or weakened plane type designed to establish position of any crack caused by contraction while providing no space for expansion of pavement beyond original length. CorrugationsRegular transverse undulation in surface of pavement consisting of alternate valleys and crests. CracksApproximately vertical cleavage due to natural causes or traffic action. CrazingPattern cracking extending only through surface layer, a result of more drying shrinkage in surface than interior of plastic concrete. D LinesDisintegration characterized by successive formation of series of fine cracks at rather close intervals paralleling edges, joints and cracks, and usually curving across slab corners. Initial cracks forming very close to slab edge and additional cracks progressively developing, ordinarily filled with calcareous deposit. Dense and Open Graded AggregatesDense applies to graded mineral aggregate containing sufficient dust or mineral filler to reduce all void spaces in compacted aggregate to exceedingly small diameters approximating size of voids in filler itself, may be either coarse or fine graded; open applies to graded mineral aggregate containing no mineral filler or so little that void spaces in compacted aggregate are relatively large. DewaterTo remove water by pumping, drainage or evaporation or a dewatering screw. DisintegrationDeterioration into small fragments from any cause. DistortionAny deviation of pavement surface from original shape. Expansion JointJoint permitting pavement to expand in length. FaultingDifferential vertical displacement of slabs adjacent to joint or crack. FlumeAn open conduit of wood, concrete or metal. GradationSieve analysis of aggregates, a general term to describe the aggregate composition of a mix.
233

Gradation AggregatesPercentages of aggregate in question which fall into specified size limits. Purpose of grading aggregates is to have balanced gradation of aggregate so that voids between sizes are progressively filled with smaller particles until voids are negligible. Resulting mix reaches highest mechanical stability without binder. GranitesCrystalline, even-grained rocks consisting essentially of feldspar and quartz with smaller amounts of mica and other ferro-magnesian minerals. GravelGranular, pebbly material (usually coarser than 1/4" in diameter) resulting from natural disintegration of rock; usually found intermixed with fine sands and clay; can be identified as bank, river or pea gravel; rounded character of some imparted by stream action. GravityThe force that tends to pull bodies towards the center of mass, to give bodies weight. GritA coarse sand formed mostly of angular quartz grains. GumboSoil of finely divided clays of varying capillarity. HollowsDeficiencies in certain fractions of a pitrun gravel. IgneousNatural rock composed of solidified molten material. Lime RockNatural material essentially calcium carbonate with varying percentages of silica; hardens upon exposure to elements; some varieties provide excellent road material. LimestoneNatural rock of sedimentary origin composed principally of calcium carbonate or calcium and magnesium carbonates in either its original chemical or fragmental, or recrystallized form. LoamSoil which breaks up easily, usually consisting of sand, clay, and organic material. LoessAn unstratified deposit of yellow-brown loam. Manufactured SandNot natural occurring sand, -38" material made by crushing +38" material. MeshThe number of openings per lineal inch in wire screen.
234

Metamorphic RockPre-existing rock altered to such an extent as to be classed separately. One of the three basic rock formations, including igneous and sedimentary. MicronA unit of length; one thousandth of a millimeter. Mineral Dust or FillerVery finely divided mineral product, great bulk of which will pass No. 200 sieve. Pulverized limestone is most commonly manufactured filler; other stone dust, silica, hydrated lime and certain natural deposits of finely divided mineral matter are also used. MuckMoist or wet decaying vegetable matter or peat. Natural CementProduct obtained by finely pulverizing calcined argillaceous limestone, to which not to exceed 5 percent of nondeleterious materials may be added subsequent to calcination. Temperature of calcination shall be no higher than necessary to drive off carbonic acid gas. OreAny material containing valuable metallic matter which is mined or worked. OutcroppingA stratum of rock or other material which breaks surface of ground. OverburdenSoil mantle, waste, or similar matter found directly above deposit of rock or sand-gravel. Paving AggregateVary greatly as to grade, quality, type, and composition; general types suitable for bituminous construction can be classified as: Crushed Stone, Gravel, Sand, Slag, Shell, Mineral Dust. PebblesRock fragments of small or moderate size which have been more or less rounded by erosional processes. PitrunNatural gravel deposits; may contain some sand, clay or silt. Portland CementProduct obtained by pulverizing clinker consisting essentially of hydraulic calcium silicates to which no additions have been made subsequent to calcination other than water or untreated calcium sulfate, except that additions not to exceed 1 percent of other materials may be interground with clinker at option of manufacturer, provided such materials have been shown to be not harmful.
235

RiprapRiprap as used for facing dams, canals, and waterways is normally a coarse, grade material. Typical general specifications would call for a minimum 160 lb./ft3 (2563 kg/m3) stone, free of cracks and seams with no sand, clay, dirt, etc. SandStandard classification of soil or granular material passing the 38" (9.52mm) sieve and almost entirely passing the No. 4 (4.76mm) sieve and predominantly retained on the No. 200 (74 micron) sieve. Sand Clay (Road Surface)Surface of sand and clay mixture in which the two materials have been blended so their opposite qualities tend to maintain a condition of stability under varying moisture content. Sand, ManufacturedNot natural occurring sand, -38" material made by crushing +38" material. SandstoneEssentially rounded grains of quartz, with or without interstitial cementing materials, with the larger grains tending to be more perfectly rounded than the smaller ones. The fracture takes place usually in the cement leaving the grains outstanding. Scalp RockRock passed over a screen and rejected waste rock. ScreeningsBroken rock, including dust, or size that will pass through 1/2" to 3/4" screen, depending upon character of stone. SedimentaryRocks formed by the deposit of sediment. Settling RockAn enlargement to permit the settlement of debris carried in suspension, usually provided with means of ejecting the material collected. ShaleMaterial composed essentially of silica and alumina with a more or less thinly laminated structure imparted by natural stratification of extremely fine sediments together with pressure. Shell AggregateApplies to oyster, clam shells, etc., used for road surfacing material; shells are crushed to size but generally must be blended with other fine sands to produce specification gradation. SieveTest screens with square openings.
236

SlagBy-product of blast furnace; usually makes good paving material, can be crushed into most any gradation; most are quite porous. SlatesRocks, normally clayey in composition, in which pressure has produced very perfect cleavage; readily split into thin, smooth, tough plates. Slope AngleThe angle with the horizontal at which a particular material will stand indefinintely without movement. Specific GravityThe ratio of the mass of a unit volume of a material at a stated temperature to the mass of the same volume of a gas-free distilled water at the same temperature. StoneAny natural rock deposit or formation of igneous. sedimentary and/or metamorphic origin, either in original or altered form. Stone-SandRefers to product (usually less than 1/2" in diameter) produced by crushing of rock; usually highly processed, should not be confused with screenings. StratumA sheet-like mass of sedimentary rock or earth of one kind, usually in layers between bed of other kinds. Sub-GradeNative foundation on which is placed road material or artificial foundation, in case latter is provided. Sub-SoilBed or earth immediately beneath surface soil. TailingsStones which, after going through crusher, do not pass through the largest openings on the screen. Top-Soil (Road Surface)A variety of surfacing used principally in southeastern states, being stripping of certain top-soils containing natural sand-clay mixture. When placed on road surface, wetted and puddled under traffic, it develops considerable stability. TrapIncludes dark-colored, fine-grained, dense igneous rocks composed of ferro-magnesian minerals, basic feldspars, and little or no quartz; ordinary commercial variety is basalt, diabase, or gabbro. ViscosityThe measure of the ability of a liquid or solid to resist flow. A liquid with high viscosity will resist flow more readily than a liquid with low viscosity.
237

VoidsSpaces between grains of sand, gravel or soil that are occupied by water or air or both. WeirA structure for diverting or measuring the flow of water.
238
NOTES:
239
NOTES:
240

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SECOND EDITION

FACTS and FIGURES

KPI/JCI 2.5M pg 1/04

RELATIVE WORLD PRODUCTION BY VALUE

stone sand & gravel

Modified after Lawatscheck, 1990

Horizontal Shaft Impactors (HSI)

Horse Power Requirements

191, 239, 240 6

Typical Gradation Curve

GENERAL INFORMATION ON THE INERT MINERAL (AGGREGATE) INDUSTRY

SIEVE ANALYSIS ENVELOPE

0 100 50 30 16 8 4 Standard sizes of square-mesh sieves

EXAMPLE OF ALLOWABLE GRADATION ZONE IMPORTANCE OF GRADATION CONCRETE

Allowable Cumulative Min. Max. 0 0 0 10 30 55 80 92 100 10 35 55 75 90 98 100 FIGURE NO. 3

Sample Tested IndivCumuldual tive 0 0 4 11 27 28 18 8 4 4 15 42 70 88 96 100

TYPICAL GRADATION CURVES FOR GRAVEL DEPOSITS

TYPICAL GRADATION CURVES FOR LIMESTONE QUARRY RUN

PIONEER APRON FEEDERS

STANDARD HOPPER APPROXIMATE CAPACITIESAPRON FEEDERS

RECIPROCATING PLATE FEEDERS

APPROXIMATE PER HOUR CAPACITIES OF PIONEER APRON FEEDERS ACCORDING TO WIDTH

.762 m Wide mt 67 102 134 169 202 236 269

PIONEER VIBRATING FEEDERS

VIBRATING FEEDERSAPPROXIMATE CAPACITY*

270 290 305 325 345 365

246 264 278 296 314 332

315 337 360 382 404 427

287 307 328 348 368 389

473 507 541 575 609 642

431 462 493 524 555 585

STANDARD HOPPER APPROXIMATE CAPACITIES VIBRATING FEEDERS

BELT FEEDER CAPACITY (TPH)

Belt Speed FPM

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

PIONEER JAW CRUSHING PLANTS

Rubber Tire Mounted

PIONEER JAW CRUSHERS APPROXIMATE JAW CRUSHERS GRADATIONOPEN CIRCUIT

APPROXIMATE GRADATIONS AT PEAK TO PEAK CLOSED SIDE SETTINGS

6" 152 mm 100

31.8 38.1 50.8 mm mm mm

63.5 76.2 89.1 mm mm mm

4" 2" 8" 4"

LEGENDARY JAW CRUSHERSHORSEPOWER REQUIRED AND APPROXIMATE CAPACITIES IN TPH

63 95 142 86 124 165 188 213 290

239 378 313 530 407 407 438

273 433 357 610 465 465 500

690 522 522 562

PIONEER VANGUARD JAW CRUSHERS

19 Elect Diesel mm 2650 3055 3144 3165

150 200 150 200 200 250

190 250 190 250 250 310

PIONEER PRIMARY IMPACT CRUSHERS (New Holland Style)

Close Normal Setting Setting

Close Normal Close Setting Setting Setting 100 97 100 96 90 77 64 57 50 41 32 26 20 17 12 8 5 3 2 90 75 66 56 48 43 38 31 24 19 14 12 8 5 3 2 1

Values are percent passing 100 98 89 80 67 56 50 44 37 28 23 17 15 10 6 4 3 2

4" 1 2" 3 8" 1 4"

#4 #8 #16 #30 #50 #100

600-900 600-1200 545-1091

PIONEER ANDREAS STYLE IMPACT CRUSHERS

PIONEER ANDREAS IMPACT CRUSHERS HORIZONTAL SHAFT IMPACT CRUSHER

Minimum Apron Setting 1" 1" 1"

Approximate Output Gradations-Open Circuit

APRONS: Upper @ 4" Lower @ 2"