In many urban areas, limited available landfill space and traffic congestion, with its is attendant air pollution, have become critical problems. Recycling concrete rubble is becoming an economically viable method of conserving landfill space and providing other environmental benefits. This paper reviews the economic and environmental benefits, the recycling process, and the resulting products of concrete rubble recycling. Big City Crushed Concrete has been recycling concrete rubble in Dallas for more than eight years. We currently operate four plants. Each has ajaw primary crusher and either a cone crusher , jaw crusher , or impact crusher as the secondary crusher. We operate three concrete disposal sites and have done project crushing.
The Recycling Process
There are two types of concrete recycling operations. One is the project where rubble from a runway, highway or building is recycled and reused in new construction. The other is the urban rubble disposal area where concrete from various sources is accumulated and recycled for sale to the general public. The recycling process involves crushing, removal of reinforcing steel and contaminates, screening and stockpiling the processed material. At the primary crusher, the rubble is reduced to about 4″ maximum size to free the reinforcing steel which is removed by magnets and by hand. Objectionable material including wood, plastic, and other trash is picked by hand from the conveyors and screen. The material is sized by screening with the oversized material going for further reduction to a secondary crusher then returning to the screen. After screening, the processed material is stockpiled where it will be loaded for shipment. Stockpile maintenance procedures are necessary to prevent segregation of multigraded materials like flexible base.
Concrete Recycling Crusher Equipment
Stationary recycling plants
Two-stage crushing, screening and removing the contaminants (reinforcement, paper, wood, plastics, gypsum) by magnetic separation, water cleaning or air-sifting.\r\n
Mobile recycling plants
Typically used for demolition sites with large amount of homogenous waste which is going to be reused on site. One-stage crushing only.
Most Popular Types of concrete recycling crushers
Jaw Crusher – Jaws compress the concrete between a stationary and moveable plate. Concrete is reduced in size as it travels down the length of the wedge between the two plates. Jaws are used as primary crushers and typically produce a 4″ to 8″ minus product usually used as fill.
Impact Crusher – Impactors have a spinning rotor with bars or hammers that fling the concrete into a solid plate, several plates, or rods. Impactors can be used as primary, secondary, and even tertiary crushers and produce a product typically 2″ minus used as base material in some parts of the country.
Cone Crusher – Cones are also compression type machines with the concrete being compressed between two cone shaped plates. Concrete feed to a cone is typically 6″ minus as they are used mostly as secondary crushers behind a Jaw or Impact Primary. Cones typically produce products of 1-1/2″ minus.
All of the above crusher types are available in Portable, Mobile, and Stationary configurations.
Portable crushers are mounted on rubber tired chassis and towed to the site by truck. On site they are moved by loaders or tugs.
Mobile crushers are carried to the site by truck and trailer and have their own onboard drive system typically track driven. These units move easily on sites where several moves are required.
Stationary crushers are just that they are permantly fixed to the ground. Typically used in a recycling yard where all material is trucked to the site.
Crushing at the actual construction site using portable crushers reduces construction costs and the pollution generated when compared with transporting material to and from a quarry. Large road-portable plants can crush concrete and asphalt rubble at up to 600 tons per hour or more. These systems normally consist of a rubble crusher, side discharge conveyor, screening plant, and a return conveyor from the screen to the crusher inlet for reprocessing oversize materials. Compact, self-contained mini-crushers are also available that can handle up to 150 tons per hour and fit into tighter areas. With the advent of crusher attachments – those connected to various construction equipment, such as excavators – the trend towards recycling on-site with smaller volumes of material is growing rapidly. These attachments encompass volumes of 100 tons/hour and less.
Equipment manufacturers have recently developed new or modified existing equipment specifically for concrete demolition and recycling. These developments include a wide range of breakers, crunchers, saws and crushing equipment. The manufacturers of primary crushing equipment have designed jaw and impact crushers specifically to handle flat material like pavement slabs and to reduce concrete rubble to the small size necessary to free the reinforcing.
Through our experience, we believe that the plants consisting of a jaw primary crusher with a cone, jaw, or impact secondary crusher are best for the urban recycling center. These plants are reliable and require a lower level of maintenance. However, these plants have a much higher capital cost and are not as readily portable as the closed cycle impact crushing plants. The impact crusher plants are very mobile and well suited for short-term projects.Concrete recycling crusher applied in construction concrete and asphalt rubble recycling processing plant,if you want to learn more about concrete recycling crusher,you can contact us!
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