kpi jci facts figures handbook

SECOND EDITION

FACTS and FIGURES

© KPI/JCI 2.5M pg 1/04 Printed in U.S.A.

&

Astec companies

KOLBERG-PIONEER, INC. and JCI, Asteccompanies (Nasdaq: ASTE) are a world wideand industry leaders for bulk material handlingand processing equipment manufacturing;Conveyors, Screening Plants, Pugmill Plants,Sand and Aggregate Washing/ClassifyingSystems and all types of Portable andStationary Rock Crushers for the aggregate,recycle and remediation industries under thetrade names of KOLBERG,® PIONEER®, andJCI®.

Kolberg-Pioneer, Inc. and JCI have madeevery effort to present the informationcontained in this booklet accurately.However, the information should be a generalguide and Kolberg-Pioneer, Inc. and JCI donot represent the information as exact underall conditions. Because of widely varying fieldconditions and characteristics of materialprocessed, information herein coveringmachine capacities and gradations producedare estimated only.

Products of Kolberg-Pioneer, Inc. and JCIare subject to the provisions of their StandardWarranty. All specifications are subject tochange without notice.

Emblems , , Magna Cone, Spec-Select,Kodiak, Combo, Spokane, Has All The Pieces,KOLBERG-PIONEER and JCI are trademarks of

and

2

FORWARD

Aggregate production is based on mathematicalrelationships…volumes, lengths, widths, heightsand speeds. Because of widely varying fieldconditions and characteristics of materialprocessed, information herein relating tomachine capacities and gradations produced areestimates only. Much of this data of specialinterest to producers and their employees hasbeen included in this valuable Facts and Figuresbooklet.

At the same time, we take this opportunity toacquaint you with our ever-broadening line ofequipment for aggregate producers that includes;Conveyors, Screening Plants (Horizontal, Incline,Multi-Angle, Direct Feed, Portable), Sand andAggregate Washing/Classifying Systems, alltypes of Rock Crushers (Jaw, Cone, Impact) inPortable, Stationary and Track Mounted Modelsand Pugmill Plants under the trade names of

®

and

3

RELATIVE WORLD PRODUCTIONBY 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.

Modified after Lawatscheck, 1990

Courtesy of

sand & gravel

stoneiron gold

copper

bauxite

peat

sulphur

phosphatediamondsilverplatinumzincclaysmanganesekaolineasbestos

uraniumnickellead

potassium salttalcsalt

magnesitetin

sodaboron

titaniumgypsum

chromitemolybdenum

bentonitediatomitefluorsparcobaltmicagraphitevanadiumbaritetungstenfeldsparniobiumzirconiumantimonysillimenite

USGSFIGURE NO. 1

6 5 4 3 2 1

4

TABLE OF CONTENTSAngle of Repose/Surcharge. . . . . . . . . . . . . . . . . . . . . . . . . . 179Autogenous Crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 75Belt Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Blade Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-97Capacity

Belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Cone crushers

Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 42LS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Magna Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-59

FeedersApron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Reciprocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Vibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Horizontal Shaft Impactor (HSI)

Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30New Holland style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

JawsLegendary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Vanguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Roll Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-67Screen Plants, portable . . . . . . . . . . . . . . . . . . . . . . . . . 164-166Screens

JCI Formula (using additional factors) . . . . . . . . . . . 139-158Kolberg–Pioneer Formula (VSMA factors) . . . . . . . . 79, 161

StockpileCircular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Telescoping stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188Volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . . . . 69Classifying

Controls (Spec-Select I, II and III) . . . . . . . . . . . . . . . . . 115-116Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Pipes, Velocity Flow and Friction Loss . . . . . . . . . . . . . . . . . . 111Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Weir Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 205

Coarse Material Washing. . . . . . . . . . . . . . . . . . . . . . . 91, 94-95Combo (Multi-Slope) Screens . . . . . . . . . . . . . . . . . . . . 136-138Cone Crushers

Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 34-47LS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 48-55Magna Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-59

Conveyors, Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Belt speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177, 181

Recommended by material . . . . . . . . . . . . . . . . . . . . . . . 177

5

Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Capacity, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171-172Horse Power requirements . . . . . . . . . . . . . . . . . . . . . . 179-180Idler classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Incline bulk materials, recommended. . . . . . . . . . . . . . . . . . . 168Models, sizes and selections . . . . . . . . . . . . . . . . . . . . . 182-190

CrushersCones

Kodiak Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 34-47LS Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 48-56Magna Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-59

Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-78Horizontal Shaft Impactors (HSI)


Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-27Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-67Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . 68-75

Crusher notesKodiak and LS Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Magna Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Vertical Shaft Impactor (VSI) . . . . . . . . . . . . . . . . . . . . . . . 68, 75

DataAngle of repose – surcharge . . . . . . . . . . . . . . . . . . . . . . . . . 174Belt carrying capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Belt speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Elevation, conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . 171-172Horse Power requirements . . . . . . . . . . . . . . . . . . . . . . 179-180Idler classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Incline, bulk materials, recommended . . . . . . . . . . . . . . . . . . 168Stockpile

Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Telescoping stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188Volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Weights, common materials. . . . . . . . . . . . . . . . . . . . . . . . . . 214Weir flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 205Wire mesh for vibrating screens. . . . . . . . . . . . . . . . . . . . . . . . 80

Data, Industry Terms and Definitions. . . . . . . . . . . . . . 195-231 Dredge, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Electric motors and wiring . . . . . . . . . . . . . . . . . . . . . . . 198-201Generator sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Pipes, velocity flow and friction loss. . . . . . . . . . . . . . . . 203-204Railroad ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195Riprap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126, 206-209Weights and measurers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Definitions and Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 232-238

6

Feeder CapacitiesApron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Reciprocating plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Vibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fine Material Washing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-101FM (Fineness Modulus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90General Information on the Aggregate Industry . . . . . . 3, 8-11Gradations

Aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15, 84-85ASTM C-33, C-144 . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 88-89Gravel, typical deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-78Horizontal Shaft Impactors (HSI)


Jaw Crushers, Peak to Peak (CSS) . . . . . . . . . . . . . . . . . . . . . 23Kodiak series cone crushers . . . . . . . . . . . . . . . . . 36-37, 42-43Limestone, typical quarry run . . . . . . . . . . . . . . . . . . . . . . . . . . 15LS series cone crushers. . . . . . . . . . . . . . . . . . . . . . . . . . . 48-49Magna cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-58Roll crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . 70-74Washing, classifying . . . . . . . . . . . . . . . . . . . . . . . . . . . 105, 113

Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Horizontal Shaft Impactors (HSI)

Andreas style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31New Holland style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Horse Power RequirementsConveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179-180Hammermills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Horizontal Shaft Impactors (HSI)


Jaw Crushers (Peak to Peak) . . . . . . . . . . . . . . . . . . . . . . 25, 27Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Roll Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-65Vertical Shaft Impact crushers (VSI) . . . . . . . . . . . . . . . . . . . . 69

Incline screens JCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-135Pioneer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-81

Jaw Crushers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-27Kodiak Cone crusher series . . . . . . . . . . . . . . . . . . . . 32, 34-47Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-93LS Cone crusher series . . . . . . . . . . . . . . . . . . . . . . . . 32, 48-56Magna Cone crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-59Notes (blank pages) . . . . . . . . . . 87, 117, 127, 133, 159, 167,

191, 239, 240

7

Peak to Peak Jaw crusher settings . . . . . . . . . . . . . . . . . 25, 27Pugmills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192-193Roll crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-67Screening and Washing Plants . . . . . . . . . . . . . . . . . . . 118-119Screens, calculating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Screens, JCI Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Screens, Kolberg Introduction . . . . . . . . . . . . . . . . . . . . . . . . 160Screens, Types

Combo (Multi-Slope) JCI . . . . . . . . . . . . . . . . . . . . . . . . 136-138Formula - JCI (with new factors) . . . . . . . . . . . . . . . . . . 139-158Formula - Kolberg-Pioneer (standard VSMA factors) . . . 79, 161Horizontal - JCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-132Incline - JCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-135Multi-Slope (Combo) JCI . . . . . . . . . . . . . . . . . . . . . . . . 136-138Pioneer Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Portable plants - Kolberg

KDS models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Models 241, 271, 291 . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Model 291, 391, 391-T. . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Sieve sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 80, 85-86, 88-89Units - Kolberg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162-163

Screens, wire mesh (cloth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80SE (Sand Equivalent test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Sieve sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13Spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126, 206-209Stockpile

Angle of Repose/Surcharge. . . . . . . . . . . . . . . . . . . . . . . . . . 179Circular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Telescoping Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 187-188Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . 232-238Typical Gradation Curve

Gravel Deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Limestone Quarry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Vertical Shaft Impact crushers (VSI). . . . . . . . . . . . . . . . . 68-75Washing Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

ASTM C-33, C-144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-89Blade Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-97Classifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-116Coarse material washing . . . . . . . . . . . . . . . . . . . . . . . 91, 94-97Controls (Spec-Select I, II and III) . . . . . . . . . . . . . . . . . 115-116Dredge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Fine material washing . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-101Fineness Modulus (FM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Gradation requirements. . . . . . . . . . . . . . . . . . . . . 84-86, 88-89Log Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-93Sand Equivalent test (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Screening and Washing plants. . . . . . . . . . . . . . . . . . . . 118-119

Weights and Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210World Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8

GENERAL INFORMATION ON THE INERTMINERAL (AGGREGATE) INDUSTRY

Modern civilization is based on the use of inert miner-als for concrete and asphaltic products. In truth,aggregate production is the largest single extractiveindustry in the United States. In excess of 2.8 billiontons of sand, gravel and crushed rock are producedannually. Because aggregates play such a vital role inthe continuing growth of the nation and the world,demand for all types can be expected to increase sub-stantially in the years ahead.

There is great romance about these commonplaceminerals; the earth sciences tell us a compelling storyof the evolution of the earth’s mantle and its mineralswhich man has found so valuable to the civilizingprocesses on his planet. Since the earliest Ice Age,erosion of the continental rock by earth, wind, rain andfire have resulted in fractions being carried down themountains by wind and water, the grains settling in analmost natural grading process. Other natural eventssuch as floods and upheavals caused rivers andstreams to change courses, burying river beds thathave become high production sand and gravel opera-tions in our time. Evaporation, condensation,precipitate and chemical actions, percolation andfusions have formed other rock materials that havebecome valuable aggregates in modern times.Advancements in geology and technology aid theindustry in its progress to greater knowledge aboutthese building blocks of all ages and civilizations.

Locating these minerals has become much easier,too—and just in time as recently the nation hasacknowledged the state of neglect of hundreds of thou-sands of miles of state and county roads. The massiveInterstate Program has dominated the expenditure ofroad - building funds at the expense of these ruralhighways, so that today there are vast amounts ofrepair, reclamation and replacement of roads to bedone. And, of course, locating nearby sources ofroadbed materials wherever possible will affect theeconomy of construction…and, in some cases, eventhe kind of construction as well.

9

Rapid field investigations for possible sources of min-erals have been made very simple and relativelyinexpensive by the use of portable seismic instrumentsand earth resistivity meters. The latter are especiallyeffective in locating sand, gravel and ground water bymeasuring the inherent electrical characteristics ofeach. Briefly, an alternating current is applied acrosselectrodes implanted at known spacings in the surfacesoil; the potential drop of the current between the elec-trodes indicates whether the subsurface geologyincludes any high resistance areas, indicating sand,gravel or water. Another tool, the portable seismicinstrument is used to measure the velocity of energytransmitted into the earth as deep as 1,000 feet. Thevelocity of the energy wave’s travel through the sub-surface geologic structure indicates the density orhardness of each layer or strata. For example, thevelocity of topsoil may be 3,000 feet per sec. whilelimestone, granite and other potentially useful inertmaterials may have velocities beyond 12,000 feet persec. Thus, where the occurrence of aggregate mater-ial is not always convenient to the shortest haul routesor major population centers, locating and utilizing themhave benefitted greatly by modern technology.

CLASSES OF AGGREGATESThere are two main classes of aggregates.

1. Natural aggregates in which forces of naturehave produced formations of sand and graveldeposits. These may include silts, clays or otherforeign materials which are difficult to reject. Fur-ther, gradations may be quite different thanthose required for commercial sales. To meetsuch requirements, it becomes necessary toprocess or beneficiate natural aggregatedeposits.

2. Manufactured aggregates are obtained fromdeposits or ledges of sedimentary rock (formedby sediments) or from masses of igneous rock(formed by volcanic action or intense heat).These are blasted, ripped or excavated and thencrushed and ground to specified gradations.These deposits, too, may include undesirablematerials such as shales, slates or bodies ofmetamorphic or igneous rock. Such deleteriousmaterials must be removed in the processingoperations.

10

PROCESSING OF AGGREGATESMuch of the equipment used in the processing of rawaggregates has been adapted from other mineral pro-cessing techniques and modified to meet the specificrequirements of the crushed stone, sand and gravelindustry. Other types of equipment have been intro-duced to improve efficiency and final product. Theequipment is classified in four groups.

1. Reduction equipment, jaw, cone, roll, gyratory,impact crushers and mills; these reduce materi-als to required sizes or fractions.

2. Sizing equipment: Vibratory and grizzly screensto separate the fractions in varying sizes (SeeSCREENS, page 92-97).

3. Dewatering equipment: Sand Sorters, Log Wash-ers, Sand and Aggregate preparation and Fineand Coarse recovery machines.

4. Sorting equipment. This can include variouskinds of feeder traps and conveyor arrange-ments to transfer, stockpile or hold processedaggregates.

As to method, there are two types of operations atmost sand and gravel pits and quarry operations. Theyinclude: (a) dry process; here the material is excavatedby machines or blasted loose, and is hauled to a pro-cessing plant without the use of water, and (b) wetprocess: This may involve pumping (dredge pumps) orexcavation (draglines) of the aggregate material from apit filled with water. The material enters the processingoperation with varying quantities of water.

The ideal gradation is seldom, if ever met in naturallyoccurring sand or gravel. Yet the quality and control ofthese gradations is absolutely essential to the worka-bility 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 ofmoisture, and water.

3. To keep to a minimum the volume changesresulting from the setting and hardening processand from moisture changes.

11

The influence of the aggregate on the resulting productdepends on the following characteristics:

1. The mineral character of the aggregate asrelated to strength, elasticity, and durability.

2. The surface characteristics of the particles, par-ticularly as related to workability and bondingwithin a hardened mass.Aggregate with rough surfaces or angularshapes does not place or flow as easily into theforms as smooth or rounded grains.

3. The gradation of the aggregates, particularly asrelated to the workability, density, and economyof the mix.

Of these characteristics, the first two are self-explana-tory and inherent to a particular deposit. In some casesan aggregate can be upgraded to an acceptable prod-uct by removing unsound or deleterious material, usingbenefication processes.

Gradation, however, is a characteristic which can bechanged or improved with simple processes and is theusual objective of aggregate preparation plants.

12

100

80Nos

100

-4 s

ieve

s

Nos

4-1

.5 in

. sie

ves

60

40

20

0100 50 30 16 8 4 13/4

3/81/2 11/2

Nos 1

00-4

sie

ves

Nos

4-1

.5 in

. sie

ves

SIEVE ANALYSIS ENVELOPEPercent passing by weight

Standard sizes of square-mesh sieves

Curves indicate the limits specified in ASTM for fine andcoarse aggregate

FIGURE NO. 2

EXAMPLE OF ALLOWABLE GRADATIONZONE IMPORTANCE OF GRADATION—

CONCRETETo improve workability of concrete, either the amountof water or the amount of fine particles must beincreased. Since the water-to-cement ratio is governedby the strength required in the final cured concrete,any increase in the amount of water would increasethe amount of cement in the mix. Since cement costsare much greater than aggregate, it is evident thatvarying the gradation is more economical. Most of theformula used for proportioning the components of theconcrete have been worked out as the results of actualexperimentation. They are based, however, on twofundamentals.

1. To obtain a sound concrete, all voids must befilled either with fine aggregates or cementpaste.

2. To obtain a sound concrete, the surface of eachaggregate particle should be covered withcement paste.

An ideal mix is a balance between saving on cementpaste by using fine aggregates to fill the voids, and theadded paste required to cover the surfaces of theseadditional aggregate particles.

13

ACTUAL GRADATIONThe ideal gradation is seldom, if ever, met in naturally-occurring sand or gravel. In practice, the quality of thegradation of the aggregate, the workability of the con-crete, cement and asphalt requirements must bebalanced to achieve strength and other qualitiesdesired, at minimum total cost.

Sizing of material larger than No. 8 sieve is best andmost economically done by the use of mechanicalscreens of various types, either dry or wet. In actualpractice, however, the division between coarse aggre-gates which require different equipment for sizing, isset at No. 4 sieve, (Fig. 3).

Tables have been published to facilitate these calcula-tions, and they are based on the maximum size of thecoarse aggregate which can be used for the specifictype of construction planned.

Percent Weight RetainedSieveNo.

Allowable Sample Tested

Cumulative Indiv- Cumul-Min. Max. dual tive

3⁄8" 0 0 0 0

4 0 10 4 4

8 10 35 11 15

16 30 55 27 42

30 55 75 28 70

50 80 90 18 88

100 92 98 8 96

Pan 100 100 4 100

FIGURE NO. 3

14

TYPICAL GRADATION CURVESFOR GRAVEL DEPOSITS

#200

#100#80

#60

#50#40

#30

#20

#16

#10#8

#4

/4

/8

/4

11 /4

1 /2

2

3

456

/2

6.35

9.53

19.0

25.431.838.1

50.8

76.2

102127152

12.7

100 80 60 40 20 0

SIEVE ANALYSISmminches % RETAINED

0 20 40 60 80 100

SIE

VE

SIZ

E

% PASSING

KEY:35/65 Heavy Gravel50/50 Deposit65/35 Heavy Sand

1

1

3

1

1

3

15

TYPICAL GRADATION CURVESFOR LIMESTONE QUARRY RUN

#8

#4

1/4

3/8

1/2

3/4

1

11/2

2

21/2

3

4

5

678

1012

6.35

9.53

12.7

19.0

25.4

38.1

50.8

63.5

76.2

102

127

152178203

254305

100 80 60 40 20 0

0 20 40 60 80

mminches % RETAINED

SIEVE ANALYSIS

100

% PASSING

SIE

VE

SIZ

E KEY:Top Size 30" - 36" CoarseTop Size 24" - 27" AverageTop Size 18" - 21" Fine

16

PIONEERAPRON FEEDERS

Particularly suited for wet, sticky materials, the PioneerApron Feeder provides positive feed action whilereducing material slippage. Feeder constructionincludes heavy-duty and extra-heavy-duty designsdepending upon the application.

17

STANDARD HOPPER APPROXIMATE CAPACITIES—APRON FEEDERS6 Ft 1.83 m 8 Ft. 2.44 m 10 Ft. 3.05 m 12 Ft. 3.66 m 14 Ft. 4.27 m

Width Yd.3 m3 Yd.3 m3 Yd.3 m3 Yd.3 m3 Yd.3 m3

30" ( 762 mm) Apron Feeder Without Extension 2.1 1.6 3.2 2.4 4.3 3.3 5.4 4.1 — —

30" ( 762 mm) Apron Feeder With Extension 3.3 2.5 5.8 4.4 8.3 6.4 10.8 8.2 — —

36" ( 914 mm) Apron Feeder Without Extension 2.4 1.8 3.6 2.8 4.8 3.7 6.0 4.6 7.2 5.5

36" ( 914 mm) Apron Feeder With Extension 3.6 2.8 6.3 4.8 9.0 6.9 11.7 8.9 14.5 11.1

42" ( 1067 mm) Apron Feeder Without Extension 2.6 2.0 3.9 3.0 5.3 4.0 6.6 5.0 7.9 6.0

42" ( 1067 mm) Apron Feeder With Extension 3.9 3.0 6.8 5.2 9.7 7.4 12.6 9.6 15.6 11.8

48" ( 1219 mm) Apron Feeder Without Extension — — 4.4 3.4 5.8 4.4 7.3 5.6 8.8 6.7

48" ( 1219 mm) Apron Feeder With Extension — — 7.4 5.6 10.5 8.0 13.6 10.4 16.7 12.8

Model Size Type of Approx. Capacity* Hopper Size Hopper Capacity Weight

Number in. mm Service at 60 RPM Ft. Sq. Meters Sq. Cu. Yards Cu. Meters (With Hopper)

25 RP 24 610 Standard 100-200 TPH ( 90.7 - 181 mt/h) 6 1.83 1.7 1.3 2050 lbs. 931 kg

31 RP 30 762 Standard 150-300 TPH ( 136-272 (mt/h) 6 1.83 1.7 1.3 2165 lbs. 983 kg

30 RP 30 762 Heavy Duty 150-300 TPH ( 136-272 mt/h) 6 1.83 1.7 1.3 2550 lbs. 1158 kg

37 RP 36 914 Standard 215-430 TPH ( 195-390 mt/h) 7 2.14 2.6 1.99 3175 lbs. 1441 kg



RECIPROCATING PLATE FEEDERS

NOTE: *Range is for type of feed from damp sticky to dry material.

18

Pan Travel(Ft. per Min.) Yds3 Tons Yds3 Ton Yds3 Tons Yds3 Tons Yds3 Tons Yds3 Tons

10 55 74 80 108 109 147 143 192 222 300 320 43215 83 112 120 162 164 222 214 289 333 450 480 64820 110 148 160 216 218 294 284 384 444 600 650 86425 138 186 200 270 273 369 357 482 555 750 800 108030 165 223 240 324 327 442 427 577 667 900 960 129635 193 260 280 378 382 516 500 673 778 1050 1120 151240 220 296 320 432 436 588 572 768 888 1200 1280 1728

30" Wide 36" Wide 42" Wide 48" Wide 60" Wide 72" Wide

Pan Travel(meters per

(minute) m3 mt m3 mt m3 mt m3 mt m3 mt m3 mt

3.05 42 67 61 98 83 133 109 174 170 272 245 3924.57 63 102 92 147 125 201 164 262 254 408 367 5886.10 84 134 122 196 167 267 217 348 339 544 489 7847.62 105 169 153 245 209 335 273 437 424 680 611 9089.14 126 202 183 293 250 401 326 523 510 816 734 117610.67 147 236 214 343 292 468 382 610 594 953 856 137212.19 168 269 245 392 333 533 437 697 679 1089 978 1568

.762 m Wide .914 m Wide 1.07 m Wide 1.22 m Wide 1.52 m Wide 1.83 m Wide

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, anddepth 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.

APPROXIMATE PER HOUR CAPACITIES OF PIONEER APRON FEEDERS ACCORDING TO WIDTH

19

PIONEERVIBRATING FEEDERS

Designed to convey material while separating fines,Pioneer Vibrating Feeders provide smooth, controlledfeed rates to maximize capacity. Grizzly bars aretapered to self-relieve with adjustable spacing forbypass sizing. Feeder construction includes heavy-duty deck plate with optional AR plate liners.Heavy-duty spring suspension withstands loadingimpact and assists vibration.

20

30" (.76m) 36" (.91m) 42" (1.07m) 50" 1.27m) 60" (1.5m)WIDE WIDE WIDE WIDE WIDE

RPM TPH mt/h TPH mt/h TPH mt/h TPH mt/h TPH mt/h

600 828 754650 623 568 898 818700 315 287 473 431 671 611 967 881750 270 246 337 307 507 462 720 656 1035 943800 290 264 360 328 541 493 767 698850 305 278 382 348 575 524900 325 296 404 368 609 555950 345 314 427 389 642 5851000 365 332

VIBRATING FEEDERS—APPROXIMATE CAPACITY*

CAPACITY MULTIPLIERS FOR VARIOUS FEEDER PANMOUNTING ANGLES FROM 0° TO 10° DOWN HILL—

ALL VIBRATING FEEDERS

STANDARD HOPPER APPROXIMATE CAPACITIESVIBRATING FEEDERS

Angle Down Hill 0° 2° 4° 6° 8° 10°

Multiplier 1.0 1.15 1.35 1.6 1.9 2.25

NOTE: *Capacity can vary ±25% for average quarry installations—capacity will usually begreater for dry or clean gravel. Capacity will be affected by the methods of loading,characteristics and gradation of material handled, and other factors.

Standard Feeder Size Yds.3 M3

30" x 12' ( 762mm x 3.7m) Without Extension 5.5 4.230" x 12' ( 762mm x 3.7m) With Extension 7.2 5.536" x 14' ( 914mm x 4.3m) Without Extension 7.2 5.536" x 14' ( 914mm x 4.3m) With Extension 12.6 9.636" x 16' ( 914mm x 4.9m) Without Extension 8.2 6.336" x 16' ( 914mm x 4.9m) With Extension 14.4 11.042" x 15' (1067mm x 4.6m) Without Extension 9.0 6.942" x 15' (1067mm x 4.6m) With Extension 18.0 13.842" x 17' (1067mm x 5.2m) Without Extension 10.2 7.842" x 17' (1067mm x 5.2m) With Extension 20.4 15.642" x 18' (1067mm x 5.5m) Without Extension 10.0 8.242" x 18' (1067mm x 5.5m) With Extension 21.6 16.542" x 20' (1067mm x 6.2m) Without Extension 12.0 9.242" x 20' (1067mm x 6.2m) With Extension 24.0 18.450" x 16' (1270mm x 4.9m) Without Extension 11.0 8.450" x 16' (1270mm x 4.9m) With Extension 21.6 16.550" x 18' (1270mm x 5.5m) Without Extension 12.6 9.650" x 18' (1270mm x 5.5m) With Extension 24.3 18.650" x 20' (1270mm x 6.1m) Without Extension 14.0 10.750" x 20' (1270mm x 6.1m) With Extension 27.0 20.660" x 24' (1524mm x 7.3m) Without Extension 19.6 15.060" x 24' (1524mm x 7.3m) With Extension 43.0 32.9

21

BELT FEEDER CAPACITY (TPH)

Belt Speed FPMH (inches) 10 20 30 40 50 608 30 60 90 120 150 180

9 34 68 101 135 169 203

10 38 75 113 150 188 225

11 41 83 124 168 206 248

12 45 90 135 180 225 270

13 49 98 146 195 244 293

14 53 105 158 210 262 315

8 40 80 120 160 200 240

9 45 90 135 180 225 270

10 50 100 150 200 250 300

11 55 110 165 220 275 330

12 60 120 180 240 300 360

13 65 130 195 260 325 390

14 70 140 210 280 350 420

8 50 100 150 200 250 300

9 56 113 169 225 281 338

10 62 125 187 250 312 375

11 69 137 206 275 344 412

12 75 150 225 300 375 450

13 81 162 244 325 406 487

14 87 175 262 350 437 525

24" B

ELT

FEED

ER(W

= 1

8")

30" B

ELT

FEED

ER(W

= 2

4")

36" B

ELT

FEED

ER(W

= 3

0")

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

22

PIONEER JAW CRUSHING PLANTS

Rubber Tire Mounted

Track Mounted

Stationary

24

The chart on this page is particularly useful in determiningthe percentages of various sized particles to be obtainedwhen two or more crushers are used in the same set up. It isalso helpful in determining necessary screening facilities formaking size separations.Here is an example designed to help show you how to usethe percentage charts:

To determine the amount of material passing 11⁄4" (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 lineto 11⁄4" (31.8 mm). The horizontal line shows 39% passing…or61% retained.

APPROXIMATE GRADATIONS AT PEAK TO PEAK CLOSED SIDE SETTINGSTest Test

Sieve 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 31⁄2" 4" 5" 6" 7" 8" Sieve

Sizes 19 25.4 31.8 38.1 50.8 63.5 76.2 89.1 102 127 152 178 203 Sizes

(in.) mm mm mm mm mm mm mm mm mm mm mm mm mm (mm)

12" 100 98 95 305

10" 100 97 95 90 254

8" 100 96 92 85 75 203

7" 100 97 92 85 76 65 178

6" 100 98 93 85 74 65 53 152

5" 100 97 95 85 73 62 52 40 127

4" 100 96 90 85 70 56 45 38 28 102

3" 100 93 85 75 65 50 38 32 27 23 76.2

21⁄2" 100 95 85 73 62 52 38 31 24 22 17 63.5

2" 100 96 85 70 55 47 39 28 24 20 17 13 50.8

11⁄2" 100 93 85 67 49 39 33 27 21 18 15 13 10 38.1

11⁄4" 96 85 73 55 39 31 27 23 17 15 13 10 8 31.8

1" 85 69 55 40 29 24 20 17 14 12 10 8 6 25.4

3⁄4" 66 49 39 28 21 18 15 13 11 9 8 6 5 19.0

1⁄2" 41 29 24 19 14 12 10 9 7 6 6 5 4 12.7

3⁄8" 28 21 18 14 11 9 8 7 5 5 5 4 3 9.53

1⁄4" 18 14 12 10 7 7 6 5 4 4 4 3 2 6.35

#4 12 10 9 7 5 5 4 4 3 3 3 2 1 #4

#8 6 6 5 5 4 4 3 3 2 2 2 1 0.5 #8

Values Are Percent Passing

PIONEER JAW CRUSHERSAPPROXIMATE JAW CRUSHERS GRADATION—OPEN CIRCUIT

25

LEGENDARY JAW CRUSHERS—HORSEPOWER REQUIRED AND APPROXIMATE CAPACITIES IN TPH

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 plate…consult Factory.

SIZE3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 31⁄2" 4" 5" 6" 7" 8" 9" 10" 11" 12"

19 25 32 38 51 64 76 89 102 127 152 178 203 228 254 279 304Elect Diesel mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

1016 15 25 10 12 14 19 24 281024 25 40 15 18 22 29 36 441036 40 60 22 27 33 44 55 671047 110 29 36 44 59 73 891524 40 60 36 45 54 63 721536 75 110 54 68 81 95 109 1361654 125 175 81 102 122 142 163 2041830 60 90 61 74 86 98 1232036 100 140 109 124 139 156 1872436 100 150 153 171 205 239 2732148 125 170 145 165 186 207 2482649 150 190 165 188 211 235 2822854 200 250 213 241 268 323 378 4333042 150 190 200 223 268 313 3573163 200 250 290 330 370 450 530 610 6903350 200 250 275 302 350 407 465 5223546 200 250 275 302 350 407 465 5224248 250 310 324 376 438 500 562 625 688 752 875

HP Required

(Minimum)

APPROXIMATE CAPACITIES AT PEAK TO PEAK CLOSED SIDE SETTINGS (IN TPH)*

**

**

**

**

**

27

PIONEER VANGUARD JAW CRUSHERS HORSEPOWER REQUIRED AND APPROXIMATE CAPACITIES IN TPH

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 plate…consult Factory.

SIZE3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 31⁄2" 4" 5" 6" 7" 8" 9" 10" 11" 12"

19 25 32 38 51 64 76 89 102 127 152 178 203 228 254 279 304Elect Diesel mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

2650 150 190 165 188 211 235 282

3055 200 250 265 300 334 402 471 528

3144 150 190 212 240 267 320 373 426

3165 200 250 265 305 372 459 530 611 692

3352 200 250 275 360 416 484 553

4450 250 310 423 492 574 654 735 816

HP Required

(Minimum)

APPROXIMATE CAPACITIES AT PEAK TO PEAK CLOSED SIDE SETTINGS (IN TPH)*

**

**

28

PIONEERPRIMARY IMPACT CRUSHERS

(New Holland Style)

Making a cubical product necessary for asphalt andconcrete specifications poses many equipmentproblems for the aggregate producer. Among theseproblems are abrasive wear, accessibility for hammermaintenance or breaker bar changes and bridging inthe crushing chamber.

Pioneer Impact Crusher units are designed to helpover-come problems faced by producers and at thesame time to provide maximum productivity forexisting conditions.

29

PIONEER PRIMARY IMPACT CRUSHERS(NEW HOLLAND STYLE)—APPROXIMATE PRODUCT

GRADATION—OPEN CIRCUITTest Test

Sieve SieveSizes Normal Close Normal Close Normal Close Sizes(in.) Setting Setting Setting Setting Setting Setting (mm)

6" 100 1525" 100 97 100 1374" 100 98 100 90 98 1023" 96 100 89 96 75 89 76.2

21⁄2" 90 97 80 90 66 80 63.52" 77 89 67 77 56 67 50.8

11⁄2" 64 75 56 64 48 56 38.111⁄4" 57 67 50 57 43 50 31.81" 50 58 44 50 38 44 25.43⁄4" 41 47 37 41 31 37 19.11⁄2" 32 37 28 32 24 28 12.73⁄8" 26 30 23 26 19 23 9.531⁄4" 20 23 17 20 14 17 6.35#4 17 19 15 17 12 15 #4#8 12 14 10 12 8 10 #8#16 8 9 6 8 5 6 #16#30 5 6 4 5 3 4 #30#50 3 4 3 3 2 3 #50#100 2 3 2 2 1 2 #100

3850 4654 6064

Recommended HP Approx. Capacities*Maximum

Size Electric Diesel TPH mt/h Feed Size

3850 250-300 350-450 250-450 227-409 24"

4654 300-400 450-600 400-750 364-682 30"

6064 400-600 600-900 600-1200 545-1091 40"

NOTE: *Capacity depends on feed size and gradation, type of material, etc.Approximate product gradation can be expected as shown on chart.The product will vary from that shown depending on the size and typeof feed, adjustment of lower breaker bar, etc.

Values are percent passing

30

PIONEERANDREAS STYLE

IMPACT CRUSHERS

These Impact Crushers are designed for recyclingconcrete, asphalt as well as traditional aggregatecrushing applications. The Maximum PerformanceRotor (MPR) offers the mass of a solid design with theclearances of an open configuration.

31

100%

90%

80%

70%

60%

50%

40%

30%

20%

50 mesh 8 mesh 1" 3" 10"12"

10%

0%

APRONS:Upper @ 4"Lower @ 2"

% C

umul

ativ

e P

assi

ng

Approximate Output Gradations-Open Circuit

8000 fpm

6500 fpm

5250 fpm

FEED

PIONEER ANDREAS IMPACT CRUSHERSHORIZONTAL SHAFT IMPACT CRUSHER

NOTE: *Capacity depends on feed size and gradation, type of material, etc.** Limestone and hard rock feed sizes are based on secondary applications.

Recommended HP Approx. Capacities*

Size Electric Diesel TPH mt/h

5260 300 450 250-350 227-318

4250 150-200 260 125-225 113-204

4233 100 150 75-140 68-127

Maximum Feed Size**

Size Recycle Limestone Hard Rock

5260 36"x36"x12" 10"-12" 8"-10" 1"

4250 30"x30"x12" 10"-12" 8"-10" 1"

4233 24"x24"x12" 8"-10" 6"-8" 1"

MinimumApron Setting

32

KODIAK™ AND LS CONE CRUSHER NOTES1. Capacities and product gradations produced by

cone crushers will be affected by the method offeeding, characteristics of the material fed, speed ofthe machine, power applied, and other factors.Hardness, compressive strength, mineral content,grain structure, plasticity, size and shape of feedparticles, moisture content, and other characteris-tics of the material also affect production capacitiesand gradations.

2. Gradations and capacities shown are based on atypical well graded choke feed to the crusher. Wellgraded feed is considered to be 90% - 100% pass-ing the closed side feed opening, 40% - 60%passing the midpoint of the crushing chamber onthe closed side (average of the closed side feedopening and closed side setting), and 0 - 10% pass-ing the closed side setting. Choke feed isconsidered to be material located 360 degreesaround the crushing head and approximately 6"above the mantle nut.

3. Maximum feed size is the average of the open sidefeed opening and closed side feed opening.

4. A general rule of thumb for applying cone crushersis the reduction ratio. A crusher with coarse styleliners would typically have a 6 to 1 reduction ratio.Thus, with a 3⁄4" closed side setting the maximumfeed would be 6 x 3⁄4 or 4.5 inches. Reduction ratiosof 8 to 1 may be possible in certain coarse crushingapplications. Fine liner configurations typically havereduction ratios of 4:1 to 6:1.

5. Minimum closed side setting may be greater thanpublished settings since it is not a fixed dimension.It will vary depending on crushing conditions, thecompressive strength of the material beingcrushed, and stage of reduction. The actual mini-mum closed side setting is that setting just beforethe bowl assembly lifts minutely against the factoryrecommended pressurized hydraulic relief system.Operating the crusher at above the factory recom-mended relief pressure will void the warranty, as willoperating the crusher in a relief mode (bowl float).

33

KODIAK ANDLS CONE CRUSHERS

KODIAK 300 CONE

1400 LS Cone

34

KODIAK™ OPERATING PARAMETERSThe following list outlines successful operating para-meters for the Kodiak line of crushers. These are notprioritized in any order of importance.

Material1. Material with a compressive strength greater than

40,000 pounds per square inch should bereviewed and approved in advance by the factory.

2. No more than 10% of the total volume of feedmaterial is sized less than the crusher closed sidesetting.

3. The crusher feed material conforms to the recom-mended 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.

Mechanical1. Crusher operates at factory recommended tramp

iron relief pressures without bowl float.2. Crusher support structure is level and evenly sup-

ported across all four corners. In addition thesupport structure provides adequate strength toresist static and dynamic loads.

3. Crusher is operated only when all electrical, lubri-cation and hydraulic systems are correctlyadjusted and functioning properly.

4. Lubrication low flow warning system functions cor-rectly.

5. Lubrication oil filter functions properly and showsadequate filtering capacity on its indicator.

6. Crusher drive belts are in good condition and ten-sioned to factory specifications.

7. Crusher lubrication reservoir is full of lubricant thatmeets factory requird specifications.

8. Any welding on the crusher or support structure isgrounded 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 ordevleoping cracks.

35

11. Crusher cone head is properly blocked prior totransport.

12. Only authorized OEM parts or factory approvedwear parts are used.

Application1. Reduction ratio limited to 6 to 1 below 1" closed

side setting and 8 to 1 above 1" closed side set-ting provided no bowl float occurs.

2. Manganese chamber configuration conforms tothe factory recommended application guidelines.

3. Crusher is operated at the factory recommendedrpm for the application.

4. Crusher feed is consistent providing an even flowof material, centered in the feed opening, andcovering the mantle nut at all times.

5. Crusher input horsepower does not exceed fac-tory specifications.

6. Crusher discharge chamber is kept clear of mate-rial buildup.

7. If the crusher can not be totally isolated frommetal in the feed material, a magnet should beused over the crusher feed belt.

8. Crusher feed does not fall from a height morethan 36" into the crushing chamber.

9. Crusher is always shut down prior to adjusting theclosed side setting digital readout. Crusher isnever operated at zero closed side setting.

36 KODIAK 300 CONE CRUSHER PROJECTED CAPACITY AND GRADATION CHARTSProjected Open Circuit Capacitites in tons-per-hour

ClosedSide 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

Setting(CSS) 12.7 mm 15.87 mm 19.05 mm 22.22 mm 25.4 mm 32 mm 38.1 mm 44.5 mm 50.8 mmGross

Throughput 170-210 190-240 215-270 240-300 270-330 310-385 330-415 350-440 370-460

Projected Closed Circuit Capacitites in tons-per-hourClosedSide 3⁄8" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4"

Setting(CSS) 9.52 mm 12.7 mm 15.87 mm 19.05 mm 22.22 mm 25.4 mm 32 mm

RecirculatingLoad 15% 15% 15% 17% 20% 21% 28%

GrossThroughput 130-165 170-210 190-240 215-270 240-300 270-330 310-385

NetThroughput 110-140 145-178 162-204 178-224 192-240 213-261 223-277

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.

37

KODIAK 300 CONE CRUSHERGRADATION CHART

Prod-uctSize

Crusher Closed Side Setting

5⁄16" 3⁄8" 7⁄16" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

7.94 9.52 11.11 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8mm mm mm mm mm mm mm mm mm mm mm mm

4" 100

31⁄2" 100 96

3" 100 95 90

23⁄4" 98 92 86

21⁄2" 100 95 88 81

21⁄4" 97 91 83 74

2" 100 94 86 76 65

13⁄4" 100 99 89 79 66 55

11⁄2" 100 99 97 82 68 56 45

11⁄4" 100 99 95 90 72 56 46 38

1" 100 99 95 87 79 60 45 36 29

7⁄8" 100 99 95 88 80 70 49 38 30 25

3⁄4" 100 97 95 91 83 71 61 41 32 26 21

5⁄8" 100 98 94 90 85 73 58 49 34 28 22 18

1⁄2" 99 95 89 85 75 63 50 42 28 23 19 16

3⁄8" 91 85 75 69 63 51 42 33 21 17 14 12

5⁄16" 85 75 65 61 56 43 35 27 19 15 13 10

1⁄4" 74 63 52 50 45 37 29 23 16 13 11 9

4M 58 51 42 36 33 28 21 18 14 11 9 7

5⁄32" 50 42 36 30 28 23 18 15 12 10 8 6

8M 40 35 30 26 24 20 16 12 9 7 5 4

10M 35 31 26 22 20 17 14 10 8 6 4 3

16M 28 24 21 17 15 13 10 8 6 4 3 2

30M 21 18 15 11 9 8 6 5 4 3 2 1.5

40M 18 15 13 10 8 7 5 4 3 2 1.5 1

50M 14 12 11 8 7 6 4 3 2 1.5 1 0.8

100M 11 9 8 7 6 5 4 3 1.5 1 0.5 0.5

200M 8 7 6 6 5 4 3 2 1 0.5 0.5 0.3

Estimated product gradation percentages at setting shown.

38

KODIAK 300 MANGANESECONFIGURATION

KODIAK 300 Coarse

Chamber

Bowl Liner: 456073Mantle: 456071

A B C Max. Feed Material101⁄2 111⁄2 2 11101⁄4 111⁄4 11⁄2 103⁄410 11 11⁄4 1093⁄4 103⁄4 1 8

Product Range: 1" to 21⁄2" MinusPinion Speed: 850 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

KODIAK 300 Medium Chamber

with Feed Slots


A B C Max. Feed Material71⁄2 91⁄2 11⁄4 71⁄271⁄4 91⁄4 1 671⁄8 91⁄8 7⁄8 51⁄47 9 3⁄4 41⁄2

Product Range: 3⁄4" to 13⁄4" MinusPinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

All Dimensions in inches


39



A B C Max. Feed Material77⁄16 87⁄16 11⁄4 71⁄273⁄16 83⁄16 1 671⁄8 81⁄8 7⁄8 51⁄47 8 3⁄4 41⁄2



KODIAK 300 Medium

Fine Chamber


A B C Max. Feed Material41⁄2 511⁄16

7⁄8 51⁄843⁄8 59⁄16

3⁄4 543⁄16 53⁄8 9⁄16 47⁄841⁄8 55⁄16

1⁄2 43⁄4Product Range: 1⁄2" to 7⁄8" MinusPinion Speed: 900 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)


40

KODIAK 300 Fine

Chamber


A B C Max. Feed Material35⁄16 51⁄8 3⁄4 431⁄4 5 5⁄8 33⁄433⁄16 47⁄8 1⁄2 331⁄8 43⁄4 3⁄8 21⁄4



41

CRUSHER MOTOR SHEAVE SHEAVE

LINERS PINION SPEED SHEAVE HUB BORE SHEAVE HUB

COARSE 850 RPM 10-8V-24.8 N 31⁄2 10-8V-18.0 MMEDIUM MED/FINE 900 RPM 10-8V-24.8 N 31⁄2 10-8V-19.0 M

FINE EX/FINE 950 RPM 10-8V-24.8 M 31⁄2 10-8V-20.0 M

JCI KODIAK 300 V-BELT DRIVE DATA – SINGLE MOTOR1200 RPM MOTOR – 300 HP SINGLE

42 KODIAK 400 CONE CRUSHER PROJECTED CAPACITY AND GRADATION CHARTSOpen Circuit Capacitites in tons-per-hour

ClosedSide 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

Setting(CSS) 12.7 mm 15.87 mm 19.05 mm 22.22 mm 25.4 mm 32 mm 38.1 mm 44.5 mm 50.8 mmGross

Throughput 210-260 250-315 290-365 315-395 340-425 405-505 440-550 475-595 500-625

Closed Circuit Capacitites in tons-per-hourClosedSide 3⁄8" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4"

Setting(CSS) 9.52 mm 12.7 mm 15.87 mm 19.05 mm 22.22 mm 25.4 mm 32 mm

RecirculatingLoad 15% 15% 15% 17% 20% 21% 28%Gross

Throughput 165-200 210-260 250-315 290-365 315-395 340-425 405-505Net

Throughput 140-170 178-221 212-268 241-303 252-316 269-336 292-364


43

KODIAK 400 CONE CRUSHERGRADATION CHART

Prod-uctSize


5⁄16" 3⁄8" 7⁄16" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"


4" 100

31⁄2" 100 96

3" 100 95 90

23⁄4" 98 92 86

21⁄2" 100 95 88 81

21⁄4" 97 91 83 74

2" 100 94 86 76 65

13⁄4" 100 99 89 79 66 55

11⁄2" 100 99 97 82 68 56 45

11⁄4" 100 99 95 90 72 56 46 38

1" 100 99 95 87 79 60 45 36 29

7⁄8" 100 99 95 88 80 70 49 38 30 25

3⁄4" 100 97 95 91 83 71 61 41 32 26 21

5⁄8" 100 98 94 90 85 73 58 49 34 28 22 18

1⁄2" 99 95 89 85 75 63 50 42 28 23 19 16

3⁄8" 91 85 75 69 63 51 42 33 21 17 14 12

5⁄16" 85 75 65 61 56 43 35 27 19 15 13 10

1⁄4" 74 63 52 50 45 37 29 23 16 13 11 9

4M 58 51 42 36 33 28 21 18 14 11 9 7

5⁄32" 50 42 36 30 28 23 18 15 12 10 8 6

8M 40 35 30 26 24 20 16 12 9 7 5 4

10M 35 31 26 22 20 17 14 10 8 6 4 3

16M 28 24 21 17 15 13 10 8 6 4 3 2

30M 21 18 15 11 9 8 6 5 4 3 2 1.5

40M 18 15 13 10 8 7 5 4 3 2 1.5 1

50M 14 12 11 8 7 6 4 3 2 1.5 1 0.8

100M 11 9 8 7 6 5 4 3 1.5 1 0.5 0.5

200M 8 7 6 6 5 4 3 2 1 0.5 0.5 0.3


44

KODIAK 400 MANGANESECONFIGURATION

KODIAK 400 Coarse

Chamber


A B C Max. Feed Material111⁄2 13 2 121⁄4111⁄4 123⁄4 11⁄2 1211 121⁄2 11⁄4 10

103⁄4 121⁄4 1 8Product Range: 1" to 21⁄2" MinusPinion Speed: 850 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)


with Feed Slots


A B C Max. Feed Material811⁄16 103⁄16 11⁄4 91⁄281⁄2 10 1 783⁄8 97⁄8 7⁄8 51⁄481⁄4 93⁄4 3⁄4 41⁄2




45



A B C Max. Feed Material711⁄16 93⁄16 11⁄4 81⁄271⁄2 9 1 773⁄8 87⁄8 7⁄8 51⁄471⁄4 83⁄4 3⁄4 41⁄2


KODIAK 400 Medium Fine

Chamber


A B C Max. Feed Material5 63⁄8 1 53⁄4

47⁄8 61⁄4 7⁄8 51⁄443⁄4 61⁄8 3⁄4 41⁄245⁄8 6 5⁄8 33⁄4

Product Range: 1⁄2" to 7⁄8" MinusPinion Speed: 900 to 950 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)



46

KODIAK 400 Fine

Chamber


A B C Max. Feed Material23⁄4 41⁄4 3⁄4 31⁄225⁄8 41⁄8 5⁄8 33⁄821⁄2 4 1⁄2 31⁄423⁄8 37⁄8 3⁄8 31⁄8


KODIAK 400 Extra FineChamber


A B C Max. Feed Material21⁄8 25⁄8 5⁄8 27⁄82 31⁄2 1⁄2 23⁄4

17⁄8 33⁄8 3⁄8 25⁄813⁄4 31⁄4 1⁄4 21⁄2




47

TOSH.CRUSHER SHEAVE MOTOR SHEAVE WEG DRIVE DRIVE

LINERS PINION SPEED SHEAVE HUB BORE SHEAVE HUB BORE TOS BORE WEG NUMBER NUMBER

12-8V-24.8 N 41⁄2 6-8V-18.0 J 37⁄8 35⁄8 70141312-8V-24.8 N 41⁄2 6-8V-19.0 J 37⁄8 35⁄8 70110312-8V-24.8 N 41⁄2 6-8V-20.0 M 37⁄8 35⁄8 701412

JCI KODIAK 400 V-BELT DRIVE DATA – DUAL MOTOR1200 RPM MOTOR – 200 HP SINGLE – “WEG 586/7” – “TOSHIBA N587UZ”

48 1200 LS / 1400 LS CONE CRUSHER PROJECTED CAPACITY AND GRADATION CHARTSOpen Circuit Capacitites in tons-per-hour

ClosedSide 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"

Setting 12.7 15.87 19.05 22.22 25.4 32 38.1 44.5 50.8(CSS) mm mm mm mm mm mm mm mm mmGross 1200LS 125-165 140-195 165-220 180-245 200-270 220-320 240-345 260-365 270-385

Throughput 1400LS 170-215 200-255 225-285 230-305 240-350 265-390 295-405 315-450 330-480

Closed Circuit Capacitites in tons-per-hourClosedSide 1⁄4" 5⁄16" 3⁄8" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1"

Setting 6.35 7.94 9.52 12.7 15.87 19.05 22.22 25.4(CSS) mm mm mm mm mm mm mm mm

Recirculating Load 15% 15% 16% 20% 20% 20% 26% 28%

Gross 1200LS 75-90 90-105 115-145 145-190 165-220 185-250 205-275 225-300Throughput 1400LS 115-145 145-190 190-235 225-280 240-315 245-335 265-375

Net 1200 LS 64-77 77-90 97-122 116-152 132-176 148-200 152-204 162-216Throughput 1400LS 98-123 122-160 152-188 180-224 192-252 181-248 191-270


49

1200 LS / 1400 LS CONE CRUSHERGRADATION CHART

Prod-uctSize


5⁄16" 3⁄8" 7⁄16" 1⁄2" 5⁄8" 3⁄4" 7⁄8" 1" 11⁄4" 11⁄2" 13⁄4" 2"


4" 100

31⁄2" 100 96

3" 100 95 90

23⁄4" 98 92 86

21⁄2" 100 95 88 81

21⁄4" 97 91 83 74

2" 100 94 86 76 65

13⁄4" 100 97 88 79 66 55

11⁄2" 100 96 91 80 68 56 45

11⁄4" 100 97 90 83 70 56 46 38

1" 100 99 90 82 72 58 45 36 29

7⁄8" 100 99 93 86 74 64 48 38 30 25

3⁄4" 100 97 94 87 80 65 54 40 32 26 21

5⁄8" 98 94 87 80 69 55 46 34 28 22 18

1⁄2" 100 95 88 80 69 58 47 39 28 23 19 16

3⁄8" 91 84 73 63 52 44 37 28 21 17 14 12

5⁄16" 85 74 63 54 46 37 31 25 19 15 13 10

1⁄4" 74 61 50 44 36 32 26 21 16 13 11 9

4M 58 48 42 35 32 26 21 18 14 11 9 7

5⁄32" 50 41 36 30 28 23 18 15 12 10 8 6

8M 40 35 30 26 24 20 16 12 9 7 5 4

10M 35 31 26 22 20 18 14 10 8 6 4 3

16M 28 24 21 17 15 13 10 8 6 4 3 2

30M 20 18 15 11 9 8 6 5 4 3 2 1.5

40M 18 15 14 10 8 7 5 4 3 2 1.5 1

50M 14 12 12 8 7 6 4 3 2 1.5 1 0.8

100M 11 9 9 7 6 5 4 3 1.5 1 0.5 0.5

200M 8 7 6 6 5 4 3 2 1 0.5 0.5 0.3


50

LS SERIES CRUSHER MANGANESECONFIGURATIONS

1200LSEnlarged

Feed Coarse

Chamber


A B C Max. Feed Material83⁄4 10 2 93⁄883⁄8 91⁄2 11⁄2 981⁄8 91⁄4 11⁄4 81⁄877⁄8 9 1 41⁄2

Product Range: 1" to 2" MinusPinion Speed: 750 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

1200LSCoarse

Chamber



81⁄2 91⁄2 11⁄2 981⁄4 91⁄4 11⁄4 83⁄48 9 1 5




51

1200LSMedium

FineChamber



37⁄8 51⁄8 7⁄8 41⁄233⁄4 5 3⁄4 43⁄831⁄2 43⁄4 1⁄2 4



52



COARSE 750 RPM 6-8V-24.8 M 215⁄16 6-8V-16.0 JMEDIUM 800 RPM 6-8V-24.8 M 215⁄16 6-8V-17.0 J

MED/FINE 850 RPM 6-8V-24.8 M 215⁄16 6-8V-18.0 JFINE EX/FINE 900 RPM 6-8V-24.8 M 215⁄16 6-8V-19.0 J

JCI 1200LS V-BELT DRIVE DATA – SINGLE MOTOR1200 RPM MOTOR – 200 HP SINGLE

1800 RPM MOTOR – 200 HP SINGLE



COARSE 725 RPM 8-8V-30 N 8-8V-12.5 JMEDIUM 775 RPM 8-8V-30 N 8-8V-13.2 J

MED/FINE 825 RPM 8-8V-30 N 8-8V-14.0 JFINE EX/FINE 875 RPM 8-8V-24.8 N 8-8V-12.5 J

53

1400LSCoarse

Chamber


A B C Max. Feed Material111⁄4 12 2 115⁄8103⁄4 111⁄4 11⁄2 11101⁄2 11 11⁄4 8101⁄4 103⁄4 1 6

Product Range: 1" to 21⁄2" MinusPinion Speed: 700 to 800 RPMReduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)

1400LSMediumChamber


A B C Max. Feed Material83⁄4 91⁄2 11⁄4 91⁄881⁄2 91⁄4 1 87⁄883⁄8 91⁄8 7⁄8 881⁄4 9 3⁄4 4

Product Range: 5⁄8" to 1" MinusPinion Speed: 700 to 850 RPMReduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowlfloat occurs then you have gone beyond the allowable reductionratio.)



54

1400LSMedium

FineChamber



33⁄4 51⁄4 7⁄8 41⁄235⁄8 51⁄8 3⁄4 43⁄831⁄2 5 5⁄8 41⁄4


1400LS Fine

Chamber


A B C Max. Feed Material21⁄2 41⁄8 3⁄4 31⁄423⁄8 4 5⁄8 31⁄821⁄4 37⁄8 1⁄2 311⁄8 33⁄4 3⁄8 3




55



COARSE 750 RPM 10-8V-24.8 N 31⁄2 10-8V-16.0 MMEDIUM 800 RPM 10-8V-24.8 N 31⁄2 10-8V-17.0 MMED/FINE 850 RPM 10-8V-24.8 N 31⁄2 10-8V-18.0 M

FINE 900 RPM 10-8V-24.8 N 31⁄2 10-8V-19.0 M

X/FINE 950 RPM 10-8V-24.8 N 31⁄2 10-8V-20.0 M

JCI 1400LS V-BELT DRIVE DATA – SINGLE MOTOR1200 RPM MOTOR – 300 HP SINGLE

1800 RPM MOTOR – 300 HP SINGLE



COARSE 725 RPM 12-8V-30.0 P 12-8V-12.5 MMEDIUM 775 RPM 12-8V-30.0 P 12-8V-13.2 M

MED/FINE 825 RPM 12-8V-30.0 P 12-8V-14.0 MFINE EX/FINE 875 RPM 12-8V-24.8 N 12-8V-12.5 M

FEED OPENING & APPROXIMATE CAPACITY VS. SETTINGMAGNA-CONE™ M6000 CONE CRUSHER—OPEN CYCLE

See Notes (Page 31)

APPROXIMATE PRODUCT GRADATIONMAGNA-CONE™ M5000 AND M6000 CONE CRUSHER

IN OPEN CYCLE—CLOSED SIDE SETTINGSee Notes (Page 31)

in. mm in. mm in. mm in. mm in. mm TPH mt/h3⁄4" 19 77⁄16 189 85⁄16 211 195-245 177-222

7⁄8" 22 79⁄16 192 87⁄16 214 210-270 190-245

1" 25 91⁄2 241 101⁄2 267 75⁄8 194 89⁄16 217 225-285 204-259

11⁄4" 32 93⁄4 248 1011⁄16 271 715⁄16 202 813⁄16 224 250-315 227-286

11⁄2" 38 101⁄16 256 1015⁄16 278 83⁄16 208 9 229 280-350 254-318

13⁄4" 44 105⁄16 262 113⁄16 284 310-390 281-354

2" 51 109⁄16 268 117⁄16 290 335-425 304-386

21⁄4" 57 1013⁄16 275 1111⁄16 297 365-460 331-417

Coarse Bowl Coarse Bowl Medium Bowl Medium BowlClosed Side Feed Opening Feed Opening Feed Opening Feed Opening Open Cycle

Setting @ Closed Stroke @ Open Stroke @ Closed Stroke @ Open Stroke Capacity

Test TestSieve SieveSizes 5⁄8" 3⁄4" 1" 11⁄4" 11⁄2" 13⁄4" 2" 21⁄4" Sizes

in. 16 mm 19 mm 25 mm 32 mm 38 mm 44 mm 51 mm 57 mm mm5" 100 127

4" 100 100 94 102

3" 100 97 93 82 76

21⁄2" 100 95 90 85 75 64

2" 100 94 87 82 75 65 51

11⁄2" 100 94 83 75 66 60 47 38

11⁄4" 100 97 90 75 60 52 49 41 32

1" 95 90 75 55 46 43 40 32 25

3⁄4" 83 75 54 40 35 32 30 25 19

1⁄2" 55 45 35 27 24 22 20 17 13

3⁄8" 39 34 28 22 20 18 17 13 10

1⁄4" 30 27 22 18 15 14 13 9 6

#4 25 22 18 15 13 11 10 7 #4

#8 19 16 13 10 8 7 5 4 #8

#16 15 12 10 8 7 5 4 3 #16

#40 11 9 8 5 4.5 3.5 3 2 #30

#50 8 6 5 3.5 3 2.5 1.5 1 #50

#100 4 2 2 1.5 1 0.9 0.5 0.5 #100

Values Shown ArePercent Passing

56

57

FEED OPENING & APPROXIMATE CAPACITY VS. SETTINGMAGNA-CONE™ M5000 CONE CRUSHER—OPEN CYCLE

See Notes (Page 31)

APPROXIMATE PRODUCT GRADATIONMAGNA-CONE™ M5000F AND M6000F FINE HEAD CONE

CRUSHER IN OPEN CYCLE—CLOSED SIDE SETTINGSee Notes (Page 31)

in. mm in. mm in. mm in. mm in. mm TPH mt/h5⁄8" 16 71⁄8 181 77⁄8 200 135-175 123-159

3⁄4" 19 71⁄4 184 8 203 145-185 132-168

7⁄8" 22 85⁄8 219 93⁄8 238 73⁄8 187 81⁄8 206 155-195 141-177

1" 25 83⁄4 222 91⁄2 241 71⁄2 190 81⁄4 210 170-215 154-195

11⁄4" 32 9 229 93⁄4 248 73⁄4 197 81⁄2 216 195-245 177-222

11⁄2" 38 91⁄4 235 10 254 210-270 190-245

13⁄4" 44 91⁄2 241 101⁄4 260 235-300 213-272

2" 51 93⁄4 248 101⁄2 267 260-330 236-300

Coarse Bowl Coarse Bowl Medium Bowl Medium BowlClosed Side Feed Opening Feed Opening Feed Opening Feed Opening Open Cycle

Setting @ Closed Stroke @ Open Stroke @ Closed Stroke @ Open Stroke Capacity

Test TestSieve SieveSizes 3⁄8" 1⁄2" 5⁄8" 3⁄4" 1" Sizes

in. 10 mm 13 mm 16 mm 19 mm 25 mm mm2" 100 51

11⁄2" 100 94 38

11⁄4" 100 97 90 32

1" 100 95 90 75 25

3⁄4" 100 95 83 75 54 19

5⁄8" 95 86 75 60 46 16

1⁄2" 86 75 56 45 35 13

3⁄8" 75 56 41 36 30 10

1⁄4" 42 32 31 28 24 6

#4 28 27 26 23 19 #4

#8 23 21 20 17 14 #8

#16 17 16 15 13 11 #16

#30 12 11 11 10 8 #30

#50 8 8 8 6 5 #50

#100 5 4 4 2 2 #100

Values Shown ArePercent Passing

58

in. mm in. mm in. mm in. mm in. mm TPH mt/h TPH mt/h3⁄8" 10 21⁄8 54 31⁄2 89 150-190 136-172 120-150 109-1361⁄2" 13 21⁄4 57 35⁄8 92 160-205 145-186 130-165 118-1505⁄8" 16 311⁄16 94 53⁄16 132 23⁄8 60 33⁄4 95 175-225 159-204 140-180 127-1633⁄4" 19 37⁄8 98 55⁄16 135 21⁄2 64 37⁄8 98 195-250 177-227 155-200 141-1817⁄8" 22 41⁄16 103 51⁄2 140 210-270 190-245 170-215 154-1951" 25 41⁄4 108 55⁄8 143 230-295 209-268 185-235 168-213

Coarse Bowl Coarse Bowl Fine Bowl Fine Bowl Capacity (Total) Capacity (Net)Closed Side Feed Opening Feed Opening Feed Opening Feed Opening See Note 3 See Note 4

Setting @ Closed Stroke @ Open Stroke @ Closed Stroke @ Open Stroke (Page 31) Open (Page 31) Closed

in. mm in. mm in. mm in. mm in. mm TPH mt/h TPH mt/h3⁄8" 10 17⁄8 48 31⁄8 79 105-135 95-122 85-110 77-1001⁄2" 13 35⁄8 92 45⁄8 117 2 51 31⁄4 82 115-150 104-136 90-120 82-1095⁄8" 16 33⁄4 95 43⁄4 121 21⁄8 54 33⁄8 86 125-165 113-150 100-130 91-1183⁄4" 19 37⁄8 98 47⁄8 124 21⁄4 57 31⁄2 89 140-180 127-163 110-145 100-1327⁄8" 22 4 102 5 127 155-200 141-181 125-160 113-1451" 25 41⁄8 105 51⁄8 130 170-215 154-195 135-170 122-154

Coarse Bowl Coarse Bowl Fine Bowl Fine Bowl Capacity (Total) Capacity (Net)Closed Side Feed Opening Feed Opening Feed Opening Feed Opening See Note 3 See Note 4

Setting @ Closed Stroke @ Open Stroke @ Closed Stroke @ Open Stroke (Page 31) Open (Page 31) Closed

FEED OPENING & APPROXIMATE CAPACITY VS. SETTING—M5000F CONE CRUSHER—See Notes (Page 31)

FEED OPENING & APPROXIMATE CAPACITY VS. SETTING—M6000F CONE CRUSHER—See Notes (Page 31)

59

MAGNA CONE™ CRUSHER NOTES

1. Capacities and product gradations produced bycone crushers will be affected by the method offeeding, characteristics of the material fed, speed ofthe machine, power applied, and other factors.

Properly controlled, continuous feeding of recom-mended size material uniformly around the feedopening of a cone crusher is essential for maximumproduction.

Hardness, compressive strength, mineral content,grain structure, plasticity, size and shape of feedparticles, moisture content, and other characteris-tics of the material affect production capacities andgradations.

2. Minimum closed side setting may be greater thanlisted since it is not a fixed dimension. It will varydepending on crushing conditions, the compressivestrength of the material being crushed, and stage ofreduction. The actual closed side settings is thatsetting just before the bowl assembly lifts minutelyagainst the factory recommended pressurizedhydraulic relief system. Operating the crusher atabove the factory recommended relief pressure willvoid the warranty, as will operating the crusher in arelief mode.

3. Total TPH through crusher including recirculatingload.

4. Net TPH of product in closed cycle. Capacity basedon 20% recirculating load. Screen opening forclosed cycle must be something larger than crusherCSS to maintain recirculating load to maximum of20%.

60

PIONEER ROLL CRUSHERS APPROXIMATE TWIN AND TRIPLE ROLLCRUSHER GRADATION—OPEN CIRCUIT

TestSieveSizes(in.)

TestSieveSizes(mm)

Roll Crusher Settings

1⁄4" 3⁄8" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 4"

6.35 9.53 12.7 19.0 25.4 31.8 38.1 50.8 63.5 76.2 102mm mm mm mm mm mm mm mm mm mm mm

8" 203

6" 152

5" 127

4" 85 102

3" 85 63 75.2

21⁄2" 85 70 50 63.5

2" 85 69 54 36 50.8

11⁄2" 85 62 50 37 26 38.1

11⁄4" 85 70 50 40 31 22 31.8

1" 85 70 52 38 31 25 17 25.4

3⁄4" 85 65 50 36 27 24 19 14 19.0

1⁄2" 85 60 40 29 24 20 16 14 10 12.7

3⁄8" 85 65 40 27 22 19 15 13 11 8 9.53

1⁄4" 85 58 41 24 19 16 14 11 9 8 5 6.35

#4 61 39 26 18 15 13 11 9 7 6 4 #4

#8 31 20 16 12 10 8 7 6 5 4 3 #8

#16 16 12 9 7 6 5 4 3 2 2 2 #16

#30 9 7 5 4 3 3 3 2 1 1 1 #30

#50 6 4 3 3 2 2 2 1 0.5 0.5 0.5 #50

#100 4 3 2 2 1 1 1 0.5 0 0 0 #100

Gradation result may be varied to greater fines content by increasingfeed and corresponding horsepower.

Values Shown are

Per Cent Passing

61

PIONEER ROLL CRUSHERS APPROXIMATETWIN AND TRIPLE ROLL CRUSHER

GRADATION—CLOSED CIRCUIT WITH SCREEN

TestSieveSizes(in.)

TestSieveSizes(mm)

Roll Crusher Settings

1⁄4" 3⁄8" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3" 4"

6.35 9.53 12.7 19.0 25.4 31.8 38.1 50.8 63.5 76.2 102mm mm mm mm mm mm mm mm mm mm mm

4" 100 102

3" 100 79 76.2

21⁄2" 100 91 64 63.5

2" 100 85 75 48 50.8

11⁄2" 100 79 63 55 35 38.1

11⁄4" 100 90 63 50 44 29 31.8

1" 100 85 75 46 39 34 23 25.4

3⁄4" 100 80 66 55 33 28 25 18 19.0

1⁄2" 100 75 55 41 33 22 20 18 13 12.7

3⁄8" 100 80 55 36 28 24 18 16 14 10 9.53

1⁄4" 100 75 53 33 23 19 18 13 11 10 7 6.35

#4 80 55 35 22 17 15 14 10 9 8 5 #4

#8 40 25 19 14 12 10 9 7 6 5 3 #8

#16 18 14 11 8 7 6 5 4 3 3 2 #16

#30 11 8 6 5 4 4 3 3 2 2 1 #30

#50 7 5 4 3 3 3 2 2 1 1 0.5 #50

#100 4 3 3 2 2 2 1 1 0.5 0.5 0 #100

Gradation result may be varied to greater fines content by increasingfeed and corresponding horsepower.

Values Shown are

Per Cent Passing

Roll Setting 80% of

Screen Mesh Size

62

PIONEER TWIN ROLL CRUSHERSRECOMMENDED HP

Size Electric Diesel (Continuous)

2416 50 753018 100 1503024 125 1753030 200 3004022 150 2004030 250 3254240 300 4005424 250 3255536 350 475

APPROXIMATE CAPACITIES IN TPH FOR OPEN CIRCUIT(Use 85 percent of these values in closed circuit)

Roll Settings

Size 1⁄4" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2" 3"

2416 16 31 47 63 79 943018 25 50 75 100 125 150 2003024 33 66 100 133 166 200 2663030 41 82 125 166 207 276 344 4144022 34 69 103 138 172 207 276 344 4144030 53 106 160 213 266 320 426 532 6404240 70 141 213 284 354 426 568 709 8535424 44 87 131 175 228 262 350 437 5255536 65 130 195 261 326 390 522 652 782

*With smooth shells■■ No beads ■■ Bead one shell ■■ Bead two shells

*Based on 50% of theoretical ribbon of material of 100# / Ft.3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find Yd.3 /Hr. multiply by .74.For larger settings—consult Factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES)Roll 24" Dia. 30" Dia. 40" or 42" 54" or 55"

Setting Rolls Rolls Dia. Rolls Dia. Rolls1⁄4 1⁄2 1⁄2 5⁄8 3⁄43⁄8 3⁄4 3⁄4 1 11⁄81⁄2 1 1 11⁄4 11⁄23⁄4 11⁄2 11⁄2 17⁄8 21⁄41 2 2 21⁄2 3

11⁄4 23⁄8 23⁄8 27⁄8 33⁄811⁄2 23⁄4 23⁄4 31⁄8 33⁄4

2 31⁄2 33⁄4 41⁄221⁄2 43⁄8 51⁄4

3 5 6

63

PIONEER TWIN ROLL CRUSHERSRECOMMENDED HP


2416 50 753018 100 1503024 125 1753030 200 3004022 150 2004030 250 3254240 300 4005424 250 3255536 350 475

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 76.2Size mm mm mm mm mm mm mm mm mm2416 14 28 43 57 72 853018 23 45 68 91 113 136 1813024 30 60 91 121 150 181 2413030 37 74 113 150 188 227 3014022 31 62 93 125 156 188 250 312 3754030 48 96 145 193 241 290 386 483 5804240 64 128 193 257 321 386 514 644 7735424 40 79 119 159 207 238 317 396 4765536 59 118 177 237 296 354 473 591 709

*With smooth shells■■ No beads ■■ Bead one shell ■■ Bead two shells

*Based on 50% of theoretical ribbon of material of 1600 kg/m3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find cubic meters per hour, multiply by 1.6.For larger settings—consult Factory.MAXIMUM FEED SIZE VS. ROLL SETTING* (MILLIMETERS)

1016 mm or 1372 mm orRoll 610 mm 762 mm 1066 mm 1397 mm

Setting Dia. Rolls Dia.Rolls Dia. Rolls Dia. Rolls6.35 12.7 12.7 15.9 19.09.52 19.0 19.0 25.4 28.812.7 25.4 25.4 31.7 38.119.0 38.1 38.1 47.6 57.125.4 50.8 50.8 63.5 76.231.7 60.3 60.3 73.0 85.738.1 69.8 69.8 79.4 95.250.8 88.9 95.2 11463.5 111 13376.2 127 152

64

PIONEER TRIPLE ROLL CRUSHERSRECOMMENDED HP


3018 125 1753024 150 2003030 250 3754022 200 2754030 300 4004240 400 5255424 300 4005536 450 600

APPROXIMATE CAPACITIES IN TPH* FOR OPEN CIRCUIT—SINGLE FEED

(Use 85 percent of these values in closed circuit single feed only)

Roll Settings

Size 1⁄4" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 2" 21⁄2"

3018 37 75 112 150 187 2253024 52 104 156 208 260 3123030 65 130 195 260 325 3904022 58 117 176 234 292 350 468 5844030 79 159 238 318 398 476 636 7964240 105 212 317 424 530 634 848 10615424 65 131 198 262 328 392 524 6555536 97 195 293 391 489 586 782 977

*With smooth shells■■ No beads ■■ Bead two shells ■■ Bead three shells

*Based on 75% of theoretical ribbon of material of 100# / Ft.3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find Yd.3 / Hr. multiply by .74.For larger settings—consult Factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (INCHES)30" Dia. 40" or 42" 54" or 55"

Rolls Dia. Rolls Dia. RollsSmaller Larger Max. Larger Max. Larger MaxSetting Setting Feed Setting Feed Setting Feed

1⁄4 1⁄2 1 9⁄15 11⁄4 5⁄8 11⁄23⁄8 3⁄4 11⁄2 13⁄16 17⁄8 15⁄16 21⁄41⁄2 1 2 11⁄8 17⁄8 15⁄16 21⁄43⁄4 11⁄2 3 111⁄16 33⁄4 113⁄16 41⁄21 17⁄8 31⁄2 21⁄4 5 27⁄16 6

11⁄4 2 31⁄2 21⁄2 5 27⁄16 611⁄2 2 31⁄2 23⁄4 5 3 62 3 5 3 6

21⁄2 3 5 3 6

65

PIONEER TRIPLE ROLL CRUSHERSRECOMMENDED HP


3018 125 1753024 150 2003030 250 3754022 200 2754030 300 4004240 400 5255424 300 4005536 450 600

APPROXIMATE CAPACITIES IN MT/H*FOR OPEN CIRCUIT—SINGLE 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 2043024 47 94 141 189 236 2833030 59 118 177 236 295 3544022 53 106 160 212 265 317 424 5304030 72 144 216 288 361 432 577 7224240 96 192 288 384 481 576 769 9625424 59 119 180 238 297 356 475 5945536 88 177 266 355 444 532 709 886

*Based on 75% of theoretical ribbon of material of 1600 kg/m3 BulkDensity—Capacity may vary as much as ± 25%. The capacity at agiven setting is dependent on HP, slippage, type of shells and feedsize—To find cu. meters per hour, multiply by 1.6.For larger settings—consult Factory.

MAXIMUM FEED SIZE VS. ROLL SETTING* (MM)762 mm Dia. 1016 mm or 1066 mm 1372 mm or 1397 mm

Rolls Dia. Rolls Dia. RollsSmaller Larger Max. Larger Max. Larger MaxSetting Setting Feed Setting Feed Setting Feed

6.35 12.7 25.4 14.3 31.7 15.9 38.19.52 19.0 38.1 20.6 47.6 23.8 57.112.7 25.4 50.8 28.6 63.5 31.7 76.219.0 38.1 76.2 42.9 95.2 46.0 11425.4 47.6 88.9 57.1 127 61.9 15231.7 50.8 88.9 63.5 127 69.8 15238.1 50.8 88.9 69.8 127 76.2 15250.8 76.2 127 76.2 15263.5 76.2 127 76.2 152

*With smooth shells■■ No beads ■■ Bead two shells ■■ Bead three shells

66

CAPACITY MULTIPLIERS FOR OPEN CIRCUITTWIN FEED VS. SINGLE FEED

TRIPLE ROLLSTriple roll twin feed capacities are obtained by selecting a multiplierfrom the chart (depending on coarse/fine feed ratio) and applying thesame to the single feed triple roll capacity. Roll crusher capacities atgiven settings will vary depending on horsepower available, slippageof 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 Capacity Through Capacity That isCoarse/Fine Crusher Product Size

20/80 .83 .7330/70 .97 .7740/60 1.13 .8550/50 1.35 .9560/40 1.66 1.1267/33 2.00 1.3070/30 1.95 1.2480/20 1.75 1.0490/10 1.55 .82

EXAMPLE: (4030 Triple Roll)

(1) Single feed capacity for 1⁄2"—(12.7 mm—) Product = 159 TPH(144 t/h).

(2) Twin feed capacity with “feed split ratio coarse/fine” 67/33 is159 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).

(12.7 mm)

(25.4 mm)1"

1⁄2"

67

Rubber Star Gears No. ofCounter- Tires Working Springs

shaft Shell Working Centers, PerUnit Pinion Gear RPM FPM Centers, In. Inches Roll

2416 15 68 270 346 — 221⁄4-253⁄4 23018 17 82 325 530 — 281⁄4-33 23024 17 82 325 530 30-32 281⁄4-33 2

(7 x 18)3030 19 73 300 623 30-32 — 8

(7 x 18)4022 18 103 325 600 39-42 371⁄2-421⁄2 8

(10 x 22)40-43

(11 x 22)4030 19 91 310 680 39-42 371⁄2-421⁄2 8

(10 x 22)40-43

(11 x 22)4240 17 88 320 680 41-45 — 85424 19 118 310 700 53-58 53-57 8

(12 x 36) 88

5536 17 88 250 700 53-58 — 12(12 x 36)

No. ofTeeth

DETAIL DATA FOR ROLL CRUSHERPERFORMANCE (TWIN ROLLS)

Rubber Star Gears No. ofCounter- Tires Working Springs

shaft Shell Working Centers, PerUnit Pinion Gear RPM FPM Centers, In. Inches Roll3018 17 82 325 530 — 281⁄4-33 2

22

3024 18 82 325 555 30-32 281⁄4-33 2( 7 x 18)

3030 19 73 300 623 30-32 — 8( 7 x 18)

4022 19 91 310 680 39-42 371⁄2-421⁄2 8(10 x 22)

40-43 8(11 x 22)

84030 19 91 310 680 39-42 371⁄2-421⁄2 8

(10 x 22)40-43 8

(11 x 22)4240 17 88 320 680 41-45 — 125424 19 118 310 700 53-58 53-57 8

(12 x 36) 888

5536 17 88 250 700 53-58 — 12(12 x 36)

No. ofTeeth

DETAIL DATA FOR ROLL CRUSHERPERFORMANCE (TRIPLE ROLLS)

68

These Vertical Shaft Impact Crushers are best appliedin tertiary and quaternary applications and various sec-ondary applications. Rock fed to the crusher’saccelerator mechanism (table or rotor) is flung out-wards by centrifugal force against the stationary anvilsor hybrid rock shelf for free-body impacting. Theproper chamber configuration is application depen-dent.

Major crushing advantages include: precise gra-dation control; production of chips and asphaltaggregates fines; compliance with cubical andfracture count specifications, for todays tightspecification requirements such as Superpave.

PIONEERSPOKANE™ VERTICAL SHAFTIMPACT CRUSHER OPERATION

69

PIONEER VERTICAL SHAFT IMPACT CRUSHER—Specifications and Production Characteristics

Model Inch MM Mesh Inch TPH MTPH RPM H.P. Inch MM Cubic Inch Lbs-Ft Lbs Kgs

1500 (H) 2 50 #16 81⁄2 75-125 67-112 720-2000 75-150 10.4 260 4,635 1,100 13,200 6,000

1500 (A) 2 50 #4 81⁄2 75-150 67-135 720-2000 150 — — 4,635 1,100 13,700 6,000

2500 (H) 3 75 #16 113⁄8 150-250 135-223 700-1400 250 8.8 220 10,120 2,400 18,000 8,182

2500 (A) 2 50 #4 113⁄8 150-300 135-267 700-1400 300 — — 10,120 2,400 19,000 8,182

82 3 75 #16 14.0 250-400 227-356 800-1200 400-500 8.7 218 10,940 3,200 24,000 11,000

4500 (H) 3 75 4M 16.0 300-450 267-401 800-1200 400-500 10.25 (256) 17,360 3,830 29,600 13,320

4500 (H) 5 125 3⁄8" 16.0 300-450 267-401 800-1200 400-500 11.75 294 17,360 3,830 29,600 13,320

4500 (A) 21⁄2 63 #4 16.0 300-500 367-454 800-1200 400-500 — — 17,360 3,500 29,100 13,320

120 6 150 3⁄8" 18.0 300-500 267-445 800-1080 400-600 14.75 369 26,020 5,600 32,100 14,595

Minimum Standard ApproximateRecommended Capacity Impeller Recommended Explosion Weight

Maximum Closed Feed Tube Effective Crushing Table Speed Electric Table/Anvil Chamber EV-Models (ElectricFeed Size (1) Circuit Diameter Range (2) Range Horsepower Clearance Volume WK2 Shown)

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.

70

Secondary80% of Max. 50% of Max.

Max. Speed Speed Output Speed OutputSieve Size Sieve Size Feed Scalped

inches mm at 11⁄2" (1) % Passing

6" 152mm5" 125mm 100%4" 100mm 100% 993" 75mm 100% 99 972" 50mm 96 91 86

11⁄2" 37.5mm 90 81 7011⁄4" 31.5mm 86 77 631" 25.0mm 78 68 527⁄8" 22.4mm 74 64 483⁄4" 19.0mm 68 56 405⁄8" 16.0mm 62 51 361⁄2" 12.5mm 53 42 303⁄8" 9.5mm 44 34 241⁄4" 6.3mm 35 27 19

#4M 4.75mm 29 24 16#8M 2.36mm 17 15 11#16M 1.18mm 14 13 8#30M 600um 10 9 6#50M 300um 7 6 4#100M 150uM 5 4 3#200M 75uM 3 2 2

AVERAGE MATERIALS CRUSHER OUTPUT,(2) USING 3-SHOE/4-SHOE IMPELLER

PIONEER SECONDARY CRUSHING AVERAGEMATERIALS (BASALT, HARD LIMESTONE,

GRAVEL/DOLOMITE) W/STANDARD CONFIGURATIONNOTE:(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 sizedmaterial removed.

(2) Crusher outputs show average values based on field experience, and aretaken before screening product sized material out. The figures are pro-vided for estimating required screen areas and tertiary crushingequipment when used with the expected tonnage of crusher through-put. Values will differ with each specific crushing application, so thesefigures are not guarantees. Factors that can affect output gradation are:feed gradation, feed tonnage, feed friability, impeller table configura-tion, impeller speed, moisture content, closed circuit screen clothopening, available screen area and horsepower.

Model 4500 Model 120Max Feed Size Range “Cubed” 4-5" (100-125 mm) 5-6" (125-150 mm)Crusher Throughput 300-450 TPH 300-500 TPH

71

Typical Limestone in Standard Configuration

PRODUCING A COARSE GRADED MATERIAL,EMPHASIS ON CHIPS, POPCORN, AND

DIMENSIONAL PRODUCTSMaximum CrusherFeed Size: Throughput“Cubed” Capacity

Model 1500H 2" (50mm) 75-125 TPHModel 2500H 3" (75mm) 150-250 TPHModel 82H 3" (75mm) 250-400 TPH

Typical coarse gradations require 50%-80% maximum speed, 3 or4 shoe table. Typically dense gradations require 70% - 100%maximum speed, 4 or 5 shoe table.

TertiarySieve Size Sieve Size Typical Typical Typical

inches mm Feed Output Feed Output Feed Output3" 75mm 100%2" 50mm 98 100%

11⁄2" 37.5mm 94 981" 25mm 83 90 100%3⁄4" 19mm 69 78 951⁄2" 12.5mm 52 60 803⁄8" 9.5mm 40 46 621⁄4" 6.3mm 28 33 40

#4M 4.75mm 20 24 30#8M 2mm 14 15 15#16M 1.18mm 9 10 10#30M 600uM 6 7 7#50M 300uM 4 5 5#100M 150uM 3 4 4#200M 75uM 2 3 3

Models 1500H, 2500H, 82H3" Feed 2" Feed 1" Feed

72

Typical Limestone in Standard Configuration

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 prod-uct sized material, and are initial feed plus recirculating load.

Outputs: These outputs show average values based on field expe-rience crushing tough material, and indicate crusher output beforescreening product sized material out. Gradation change is due toincreased impeller speed from 50% to 100% of maximum and a dif-ference in impeller table configuration. Values will differ for eachspecific crushing application. Factors that can affect output grada-tion are: feed gradation, feed tonnage, feed friability, impeller tableconfiguration, impeller speed, moisture content, closed circuitscreen cloth opening, available screen area and horsepower.

TertiarySieve Size Sieve Size Typical Typical Typical

inches mm Feed Output Feed Output Feed Output3" 75mm 100%2" 50mm 98

11⁄2" 37.5mm 95 100%1" 25mm 87 94 100%3⁄4" 19mm 79 85 991⁄2" 12.5mm 68 73 903⁄8" 9.5mm 57 62 781⁄4" 6.3mm 46 49 63

#4M 4.75mm 37 40 52#8M 2mm 26 27 33#16M 1.18mm 17 18 21#30M 600uM 11 12 15#50M 300uM 7 8 10#100M 150uM 5 6 6#200M 75uM 4 4 4

Models 1500H, 2500H, 82H3" Feed 2" Feed 1" Feed

73

Typical Limestone inStandard Configuration

1" FEED SIZE APPLICATIONS

Models 1500H, 2500H, 82HCrushing 1" top feed size for chips, popcorn, fracture count, or amanufactured sweetener.Low RangeResulting from:• tough feed material• impeller speeds 50-80% of max.• crusher choke-fed• 3 or 4 shoe tableHigh RangeResulting 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

*Shows high range with the effect of normal field screening ineffi-ciencies. A proportional return of the coarse screen throughfractions and hydraulic classification to remove a portion of the#100 mesh minus is usually required to meet ASTM C-33 specifi-cations regarding a #4M minus gradation.

Quaternary High Range

Low High ScreenedFeed Range Range Average at #4M*

Sieve Size Sieve Sizeinches mm % Passing

1" 25mm 100% 100% 100%3⁄4" 19mm 95 99 971⁄2" 12.5mm 80 90 853⁄8" 9.5mm 62 78 701⁄4" 6.3mm 40 63 52#4 4.75mm 30 52 41 100%#8 2.36mm 15 33 24 75#16 1.18mm 10 21 15 48#30 600uM 6 15 11 34#50 300uM 5 10 7 22#100 150uM 4 6 5 13#200 75uM 3 4 3 9

Approx. Crusher Output

Models 1500H, 2500H, 82H

74

AutogenousSieve Size Sieve Size 11⁄2" 100% 100%inches mm Feed Speed Speed

2" 50mm11⁄2" 37.5mm 100%11⁄4" 31mm 99 100%1" 25mm 95 963⁄4" 19mm 90 901⁄2" 12.5mm 70 763⁄8" 9.5mm 56 581⁄4" 6.3mm 38 45

#4M 4.75mm 31 37#8M 2mm 22 25#16M 1.18mm 15 17#30M 600uM 11 13#50M 300uM 8 8#100M 150uM 6 5#200M 75uM 4 3

FullyAutogenous

Semi-Autogenous

Typical Sand and Gravel inAutogenous and Semi Autogenous

Configuration

Maximum CrusherFeed Size: Throughput“Cubed” Capacity

Model 1500A 2" 75-150 TPHModel 2500A 2" 150-300 TPHModel 4500A 21⁄2" 300-500 TPH

Based upon material weighing 2,700 lbs.. per cubic yard (1600kg/m3). Capacities may vary as much as ±25% dependent uponmethods of loading, characteristics and gradation of material, con-dition of equipment and other factors.

Models 1500A, 2500A, 4500A

75

VERTICAL SHAFT IMPACT CRUSHER CRUSHING CHAMBER TERMINOLOGY

ROTOR & HYBRIDROCK SHELFRock-on-rock crushing;rotor flings rock againstbed of rock on outerhybrid rock shelf, andexposed portion of anvilslining the hybrid rock shelffor free-body impacting.Variable reduction ratiosof 10:1 to 3:1.

FULLY AUTOGENOUS

ROTOR & ANVILCrushing chamber hasautogenous rotor andstandard stationary anvilsfor specialized crushingand materials problems;11⁄2-2" feed sizes and vari-able reduction ratios of10:1 to 3:1.

SEMI-AUTOGENOUS

SHOE & ANVILImpeller shoes in cham-ber fling rock at true rightangles to stationaryanvils; rock gradationscontrolled by impellertable speed. Variablereduction ratios of 10:1 to3:1.

STANDARD CONFIGURATION

76

PIONEER HAMMERMILLSAPPROXIMATE HAMMERMILL GRADATION—

OPEN CIRCUIT

Test TestSieve SieveSizes Sizes(in.) 1 2 3 4 5 6 7 8 9 10 (mm)

21⁄2" 100 63.52" 100 100 97 50.8

11⁄2" 100 100 97 97 95 38.111⁄4" 100 98 100 98 94 94 90 31.81" 100 97 95 97 95 90 90 84 25.43⁄4" 98 93 90 93 90 82 82 74 19.11⁄2" 90 82 79 82 79 67 67 57 12.73⁄8" 100 81 71 66 71 66 53 53 45 9.531⁄4" 100 95 64 54 50 54 50 38 38 32 6.35#4 95 89 50 41 38 41 38 27 27 22 #4#8 82 65 29 22 21 22 21 15 15 12 #8

#16 48 35 14 11 10 11 10 7 7 6 #16#30 25 20 8 6 5 6 5 4 4 3 #30#40 20 15 6 4 3 4 3 3 3 2 #40#60 14 10 4 3 2 3 2 2 2 1 #60

#100 9 7 2 2 1 2 1 1 1 0 #100

Grate Bar Selection Number

HORSEPOWER RECOMMENDED

APPROXIMATE CAPACITIES**

Size Electric Diesel (Cont.)

4034 250* 3005042 300 4004034F 500 600

*For 3⁄4" to 1" (19.1 mm to 25.4 mm) product at capacitiesindicated. More power is required for finer products and/or greatercapacities than indicated.

**Based on material weighing 2,700 lbs. per cubic yard (1600kg/m3—will vary depending on feed size, arrangement, etc.

Basic Product Size

Unit Ag. 1⁄4" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2"Size Lime 6.35 mm 12.5 mm 19.1 mm 25.4 mm 31.8 mm 38.1 mm

4034 TPH 30-50 40-70 60-100 80-120 100-140 120-160 140-180mt/h 27-45 36-64 54-91 73-109 91-127 109-145 127-163

5042 TPH 40-70 60-100 90-140 120-170 150-200 180-230 210-260mt/h 36-64 54-91 82-127 109-154 136-181 163-209 191-236

4034F TPH 30-50mt/h 27-45

Values are percent passing

77

GRATE BAR SELECTION CHARTFOR PRODUCT SIZES

5042 Hammermill

Desired Approx. Grate BarProduct Top Size Group*

1⁄4" 3⁄8" 1⁄2" 3⁄4" 1" 11⁄2" 2" 3"Ag. Lime 3⁄16" 1 8 8 970

1⁄4" 3⁄8" 2 6 6 4 9701⁄2" 1" 3 4 3 4 2 1 1 1 9703⁄4" 11⁄4" 4 4 4 7 2 1 9703⁄4" 11⁄2" 5 8 7 2 1 7007⁄8" 11⁄4" 6 4 8 3 2 7001" 11⁄4" 7 3 6 3 5 700

11⁄4" 2" 8 4 4 4 4 70011⁄2" 2" 9 8 4 5 70013⁄4" 21⁄2" 10 8 6 700

Single PassMax. Feed 8" x 8" Speed

RPM**Grate Bars—Size and Number Required

Grate Bar Size Included Angle Grate Bar Size Included Angle1⁄4" 11° 1" 11°3⁄8" 11° 11⁄2" 71⁄3°1⁄2" 11° 2" 11°3⁄4" 11° 3" 142⁄3°

4034 Hammermill

Desired Approx. Grate BarProduct Top Size Group*

1⁄4" 3⁄8" 1⁄2" 3⁄4" 1" 11⁄2" 2" 3"Ag. Lime 3⁄16" 1 4 4 1200

1⁄4" 3⁄8" 2 3 3 4 12001⁄2" 1" 3 2 3 4 1 2 1 12003⁄4" 11⁄4" 4 4 2 6 2 1 12003⁄4" 11⁄2" 5 4 6 2 1 9007⁄8" 11⁄4" 6 4 4 4 1 9001" 11⁄4" 7 3 3 4 4 900

11⁄4" 2" 8 2 4 3 4 90011⁄2" 2" 9 8 4 4 90013⁄4" 21⁄2" 10 7 6 900

Single PassMax. Feed 5" x 5" Speed

RPM**Grate Bars—Size and Number Required

Grate Bar Size Included Angle Grate Bar Size Included Angle1⁄4" 22° 1" 22°3⁄8" 22° 11⁄2" 81⁄4°1⁄2" 11° 2" 11°3⁄4" 22° 3" 161⁄2°

Three sizes of grates are available for the 4034F fine grinding mill. They are1⁄8", 1⁄4" and 3⁄8". These are usually half and half for two adjacent sizes such as1⁄8" and 1⁄4" or three equal groups of 1⁄8", 1⁄4", 3⁄8". These grates have includedangles as follows: 1⁄8", 2°, 1⁄4", 21⁄2° and 3⁄8", 3°. The total number of grates usedshould total just under 180°.

*The Grate Bars can be used in any combination as long as the totalincluded angle adds up to 176°.

**Increasing RPM of mill decreases product size.

GRATE BAR SELECTION CHARTFOR PRODUCT SIZES

5042 Hammermill

Desired Approx.Product Top Size Grate Bar(mm) (mm) Group*

6.35 9.53 12.7 19.1 25.4 38.1 50.8 76.2Ag. Lime 4.76 1 8 8 970

6.35 9.53 2 6 6 4 97012.7 25.4 3 4 3 4 2 1 1 1 97019.1 31.8 4 4 4 7 2 1 97019.1 38.1 5 8 7 2 1 70022.2 31.8 6 4 8 3 2 70025.4 31.8 7 3 6 3 5 70031.8 50.8 8 4 4 4 4 70038.1 50.8 9 8 4 5 70044.5 63.5 10 8 6 700

Single PassMax. Feed 203 mm x 203 mm Speed

RPM**Grate Bars—Size (mm) and Number Required

Grate Bar Size Included Angle Grate Bar Size Included Angle

6.35 mm 11° 25.4 mm 11°9.53 mm 11° 38.1 mm 71⁄3°12.7 mm 11° 50.8 mm 11°19.1 mm 11° 76.2 mm 142⁄3°

4034 Hammermill

Desired Approx.Product Top Size Grate Bar(mm) (mm) Group*

6.35 9.53 12.7 19.1 25.4 38.1 50.8 76.2Ag. Lime 4.76 1 4 4 1200

6.35 9.53 2 3 3 4 120012.7 25.4 3 2 3 4 1 2 1 120019.1 31.8 4 4 2 6 2 1 120019.1 38.1 5 4 6 2 1 90022.2 31.8 6 4 4 4 1 90025.4 31.8 7 3 3 4 4 90031.8 50.8 8 2 4 3 4 90038.1 50.8 9 8 4 4 90044.5 63.5 10 7 6 900

Single PassMax. Feed 127 mm x 127 mm Speed

RPM**Grate Bars—Size (mm) and Number Required

Grate Bar Size Included Angle Grate Bar Size Included Angle

6.35 mm 22° 25.4 mm 22°9.53 mm 22° 38.1 mm 81⁄4°12.7 mm 11° 50.8 mm 11°19.1 mm 22° 76.2 mm 161⁄2°

Three sizes of grates are available for the 4034F fine grinding mill. They are3.18 mm, 6.35 mm and 9.53 mm. These are usually half and half for twoadjacent sizes such as 3.18 mm and 6.35 mm or three equal groups of 3.18mm, 6.35 mm and 9.53 mm. These grates have included angles as follows:3.18 mm 2°, 6.35 mm 21⁄2°, and 9.53 mm 3°. The total number of grates usedshould total just under 180°.

*The Grate Bars can be used in any combination as long as the totalincluded angle adds up to 176°.

**Increasing RPM of mill decreases product size.

78

79

*FACTORS FOR CALCULATING SCREEN AREA**Formula: Screening Area = U

A x B x C x D x E x F x G x H x J*Basic Operating Conditions

Feed to screening deck contains 25% oversize and 40% halfsizeFeed is granular free-flowing materialMaterial weighs 100 lbs. per cu. ft.Operating slope of screen is: Inclined Screen 18° - 20° with flow rotation

Horizontal Screen 0°Objective Screening Efficiency—95%

FACTOR “A”Surface % STPHSquare Open PassingOpening Area A Sq. Ft.

4" 75% 7.69

31⁄2" 77% 7.03

3" 74% 6.17

23⁄4" 74% 5.85

21⁄2" 72% 5.52

2" 71% 4.90

13⁄4" 68% 4.51

11⁄2" 69% 4.20

11⁄4" 66% 3.89

1" 64% 3.567⁄8" 63% 3.383⁄4" 61% 3.085⁄8" 59% 2.821⁄2" 54% 2.473⁄8" 51% 2.081⁄4" 46% 1.603⁄16" 45% 1.271⁄8" 40% .953⁄32" 45% .761⁄16" 37% .581⁄32" 41% .39

FACTOR “B”(Percent of Oversize in Feed to Deck)

% Oversize 5 10 15 20 25 30 35Factor B 1.21 1.13 1.08 1.02 1.00 .96 .92

% Oversize 40 45 50 55 60 65 70Factor B .88 .84 .79 .75 .70 .66 .62

% Oversize 75 80 85 90 95Factor B .58 .53 .50 .46 .33

FACTOR “C”(Percent of Halfsize in Feed to Deck)

% Halfsize 0 5 10 15 20 25 30Factor C .40 .45 .50 .55 .60 .70 .80

% Halfsize 35 40 45 50 55 60 65Factor C .90 1.00 1.10 1.20 1.30 1.40 1.55

% Halfsize 70 75 80 85 90Factor C 1.70 1.85 2.00 2.20 2.40

FACTOR “E”(Wet Screening)

Opening 1⁄32" 1⁄16" 1⁄8" 3⁄16" 1⁄4" 3⁄8" 1⁄2" 3⁄4" 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 30Factor F 1.50 1.25 1.00 .90 .80 .75 .70 .60 .50 .30

FACTOR “G”(Screen Surface Open Area)

Factor “G” = % Open Area of Surface Being Used% Open Area Indicated in Capacity

FACTOR “D”(Deck Location)

Deck Top Second ThirdFactor D 1.00 .90 .80

FACTOR “H”(Shape of Surface

Opening)

Square . . . . . . . . . . 1.00Short Slot

(3 to 4 times Width) . . . . 1.15Long Slot

(More than 4 Times Width) . 1.20

FACTOR “J”(Efficiency)

95% . . . . . . . . . . . . 1.0090% . . . . . . . . . . . . 1.1585% . . . . . . . . . . . . 1.3580% . . . . . . . . . . . . 1.5075% . . . . . . . . . . . . 1.7070% . . . . . . . . . . . . 1.90

**Furnished by VSMA U = STPH Passing Specified Aperture

80

STANDARD WIRE MESH FOR VIBRATING SCREENSPIONEER STANDARDS

STANDARD LENGTHS OF SCREEN CLOTHS AND CLAMP BARS

Space or Clear Opening Diameter of Wire

Fractions Decimals Gauge or Decimals

of Inch of Inch Millimeters Inches of Inch Millimeters

10 x 10 mesh* .07 1.78 22 .028 0.71

8 x 8 mesh* 09 2.29 20 .034 0.86

6 x 6 mesh* .126 3.20 19 .041 1.045 x 5 mesh .153 3.89 18 .047 1.19

4 x 4 mesh .196 4.98 17 .054 1.37

3 x 3 mesh 27 6.86 16 .062 1.575⁄16" .3125 7.94 10 .135 3.433⁄8" .375 9.52 9 .148 3.76

7⁄16" .4375 11.1 8 .162 4.111⁄2" .500 12.7 7 .177 4.495⁄8" .625 15.9 6 .192 4.883⁄4" .75 19.0 5 .207 5.26

13⁄16" .8125 20.6 5 .207 5.267⁄8" .875 22.2 4 .225 5.71

1" 1.0 25.4 3 .244 6.20

11⁄8" 1.125 28.6 3 .244 6.20

11⁄4" 1.25 31.7 5⁄16" .3125 7.94

13⁄8" 1.375 34.9 5⁄16" .3125 7.94

11⁄2" 1.5 38.1 5⁄16" .3125 7.94

13⁄4" 1.75 44.4 3⁄8" .375 9.52

2" 2.0 50.8 3⁄8" .375 9.52

21⁄4" 2.25 57.1 7⁄16" .4375 11.1

21⁄2" 2.5 63.5 7⁄16" .4375 11.1

23⁄4" 2.75 69.8 7⁄16" .4375 11.11⁄8" x 2" Trilock 3.17 x 50.8 12 .105 2.673⁄16" x 3" Trilock 4.76 x 76.2 10 .135 3.431⁄4" x 3" Trilock 6.35 x 76.2 9 .148 3.763⁄8" x 4" Trilock 9.52 x 102 7 .177 4.49

NOTE: It is recommended that punched plate be used for 3" (76.2 mm) and larger screenopenings.

*Requires 3" (76.2 mm) opening. 1⁄4" (6.35 mm) wire Flat Top Weave Backing Screen.

Length of Screen Deck Length of Screen Cloth Length of Clamp Bars

Feet Meters Feet Meters Feet Meters

6 1.83 6 1.83 6 1.83

8 2.44 8 2.44 4 , 4 1.22 , 1.22

10 3.05 10 3.05 4 , 6 1.22 , 1.83

12 3.66 6 , 6 1.83 , 1.83 6 , 6 1.83 , 1.83

14 4.27 6 , 8 1.83 , 2.44 6 , 4 , 4 1.83 , 1.22 , 1.22

16 4.88 8 , 8 2.44 , 2.44 4 , 4 , 4 , 4 1.22 , 1.22 , 1.22 , 1.22

81

Permissible PermissibleVariations Variationsin Size of in Size of

Sieve Average MaximumSize Inches Opening Opening Inches

Designation (Equivalents) Millimeters (Plus or Minus) (Plus) (Equivalents) Millimeters

Openings* COARSE SERIES3" 3.00 76.2 2% 3% .190 to .320 4.8 to 8.1

21⁄2" 2.50 63.5 2% 3% .175 to .280 4.4 to 7.12" 2.00 50.8 2% 3% .160 to .245 4.1 to 6.2

11⁄2" 1.50 38.1 2% 3% .145 to .210 3.7 to 5.311⁄4" 1.25 31.7 2% 3% .140 to .190 3.5 to 4.81" 1.00 25.4 3% 5% .135 to .177 3.43 to 4.503⁄4" .750 19.1 3% 5% .122 to .154 3.10 to 3.911⁄2" .500 12.7 3% 5% .094 to .122 2.39 to 3.103⁄8" .375 9.52 3% 5% .083 to .102 2.11 to 2.591⁄4" .250 6.35 3% 5% .063 to 0.83 1.60 to 2.11

Mesh** FINE SERIESNo. 4 .187 4.76 3% 10% .045 to .066 1.14 to 1.68No. 8 .0937 2.38 3% 10% .0291 to .0433 .74 to 1.10No. 10 .0787 2.00 3% 10% .0268 to .0394 .68 to 1.00No. 16 .0469 1.19 3% 10% .0197 to .0276 .50 to .70No. 20 .0331 .84 5% 15% .0150 to .0217 .38 to .55No. 30 .0232 .59 5% 15% .0114 to .0165 .29 to .42No. 40 .0165 .42 5% 25% .0091 to .0130 .23 to .33No. 50 .0117 .297 5% 25% .0067 to .0100 .170 to .253No. 80 .0070 .117 6% 40% .0045 to .0061 .114 to .154No. 100 .0059 .149 6% 40% .0038 to .0049 .096 to .125No. 200 .0029 .074 7% 60% .0018 to .0024 .045 to .061

Size of Sieve OpeningDiameters of Wire

(Varies According to Differencesin Size of Opening)

STANDARD REQUIREMENTS FOR CERTAIN SIZES OF U.S. STANDARD SIEVES

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.

WASHINGINTRODUCTION

Clean aggregates are important to the constructionindustry. Yet producers of aggregates frequently arehard-pressed to meet all requirements for "cleanli-ness". Materials Engineers constantly strive toimprove concrete and bituminous mixes and roadbases. While hydraulic methods are the most satis-factory for cleaning aggregates to achieve the desiredresult, they are not always perfect. It is still necessaryto accept materials on the basis of some allowable per-cent of deleterious matter.

In the broadest terms, construction aggregates arewashed to make them meet specifications. Specifi-cally, however, there is more to the function of water inprocessing aggregates than mere washing. Amongthese 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 beperfect, and because some materials may require toomuch time, equipment, and water to make them con-form to specifications, it is not always economicallypractical to use such materials. It is important, there-fore, to test the source thoroughly beforehand to insurethe desired finished aggregates can be produced atreasonable cost. The project materials engineer canbe of immeasurable help in determining the economicsuitability of the material, and generally must approvethe source before production begins, anyway. Further,many manufacturers of washing equipment will exam-ine and test samples to determine whether theirequipment can do the job satisfactorily. No reputableequipment manufacturer wants to recommend hisequipment where he has a reasonable doubt about itssatisfactory performance on the job.

82

The ideal gradation is seldom, if ever, met in naturallyoccurring deposits. Yet the quality and control of thesegradations is absolutely essential to the workability anddurability of the end use. Gradation, however, is acharacteristic which can be changed or improved withsimple processes and is the usual objective of aggre-gate preparation plants.

Crushing, screening and blending are methods used toaffect the gradations of aggregates. However, evenfollowing these processes, the material may stillrequire washing to meet specification as to cleanli-ness. Also, screening is impractical smaller than No. 8mesh and hence, hydraulic separation, or classifying,becomes an important operation.

Washing and classifying of aggregates can be consid-ered in two parts, depending on the size range ofmaterial.

Coarse material - generally above 3/8" (sometimessplit at 1/4" or #4 mesh). In the washing process itusually is desired to remove foreign, objectionablematerial, including the finer particles.

Fine aggregates - from 3/8" down. In this case it gen-erally is necessary to remove dirt and silt whileretaining sand down to 100 mesh, or even 200 mesh.

83

GRADATION OF AGGREGATES

This term is used to denote the distribution of sizes ofthe particles of aggregates. It is represented by aseries of percentages by weight of particles passingone size of sieve but retained by a smaller size. Thedistribution is determined by a mechanical analysisperformed by shaking the aggregate through a seriesof nested sieves or screens, in descending order ofsize of openings. Round openings are used for largerscreens, square ones for the smaller sieves. Pre-scribed methods and prescribed openings of thescreens and sieves have been established by theASTM (American Society for Testing Materials). Thenormal series of screens and sieves is: 11⁄2", 3⁄4", 3⁄8",Numbers 4, 8, 16, 30, 50, 100, 200 mesh.

84

SIEVES FOR TESTING PURPOSESScreen or Sieve Nominal Opening EquivalentsDesignation mm inches microns

4" 101.63" 76.22" 50.811⁄2" 38.11" 25.43⁄4" 19.11⁄2" 12.73⁄8" 9.521⁄4" 6.35No.4 4.76 0.187 47606 3.36 0.132 33608 2.38 0.0937 238012 1.68 0.0661 168016 1.19 0.0469 119020 0.84 0.0331 84030 0.59 0.0232 59040 0.42 0.0165 42050 0.297 0.0117 29770 0.210 0.0083 210100 0.149 0.0059 149140 0.105 0.0041 105150 0.100 0.0039 100200 0.074 0.0029 74270 0.053 0.0021 53400 0.037 0.0015 37

85

Amounts Finer than Each Laboratory Sieve (Square-Openings), Weight PercentNormal Size

Size (Sieves with 4 in. 31⁄2 in. 3 in. 21⁄2 in 2 in. 11⁄2 in. 1 in. 3⁄4 in. 1⁄2 in. 3⁄8 in. No. 4 No. 8 No. 16Number Square Openings) (100 mm) (90 mm) (75 mm) (63 mm) (50 mm) (37.5 mm) (25.0 mm) (19.0 mm) (12.5 mm) (9.5 mm) (4.75 mm) (2.36 mm) (1.18 mm)

131⁄2 to 11⁄2 in.

100 90 - 100 25 - 60 0 - 15 0 - 5(90 to 37.5 mm)

2 21⁄2 to 11⁄2 in. 100 90 - 100 35 - 70 0 - 15 0 - 5(63 to 37.5 mm)

3 2 to 1 in. 100 90 - 100 35 - 70 0 - 15 0 - 5(50 to 25.0 mm)

357 2 in to No. 4 100 95 - 100 35 - 70 10 - 30 0 - 5(50 to 4.75 mm)

4 11⁄2 to 3⁄4 in. 100 90 - 100 20 - 55 0 - 15 0 - 5(37.5 to 19.0 mm)

467 11⁄2 in to No. 4 100 95 - 100 35 - 70 10 - 30 0 - 5(37.5 to 4.75 mm)

5 1 to 1⁄2 in. 100 90 - 100 20 - 55 0 - 10 0 - 5(25.0 to 12.5 mm)

56 1 to 3⁄8 in. 100 90 - 100 40 - 85 10 - 40 0 - 15 0 - 5(25.0 to 9.5 mm)

57 1 in. to No. 4 100 95 - 100 25 - 60 0 - 10 0 - 5(25.0 to 4.75 mm)

63⁄4 to 3⁄8 in. 100 90 - 100 20 - 55 0 - 15 0 - 5(19.0 to 9.5 mm)

673⁄4 in. to No. 4 100 90 - 100 20 - 55 0 - 10 0 - 5(19.0 to 4.75 mm)

71⁄2 in. to No. 4 100 90 - 100 40 - 70 0 - 15 0 - 5(12.5 to 4.75 mm)

83⁄8 in. to No. 8

100 85 - 100 10 - 30 0 - 10 0 - 5(9.5 to 2.36 mm)

GRADING REQUIREMENTS FOR COARSE AGGREGATES

86

Often referred to sand specifications are ASTM C-33for concrete sand and ASTM C-144 for mason sand.These specifications are often written numerically andalso shown graphically.

Limits Center specSieve % Passing % Passing

3⁄8” 100 100No. 4 95-100 97.5

8 80-100 9016 50-85 67.530 25-60 42.550 5-30 17.5

100 0-10 5200 0-3 1.5

ASTM C-144Limits Center spec

Sieve % Passing % Passing3⁄8” 100 100

No. 4 100 1008 95-100 97.5

16 70-100 8530 40-75 57.550 10-35 22.5

100 2-15 8.5200 0-10 5

SAND SPECIFICATIONS

ASTM C-33

NOTES:

87

88 ASTM C-33

100

3/8 1/4 4 6 8 10 12 16 20 30 40 50 70 80 100 140 200

9.5 6.3 4.75 3.35 2.36 2.0 1.7 1.18 850 µ M 600 425 300 212 180 150 106 75

0.375

U.S.

MM

DECIMAL 0.250 0.187 0.132 .0937 .078.066 .0469 .0331 .0234 .0165 .0117 .0083 .0070 .0059 .0041 .0029

90

80

70

60

50

40

30

20

10

0

0

10

20

30

40

50

60

70

80

90

100

PERC

ENT P

ASSI

NG

PERCENT PASSING

89

ASTM C-144

100

4 6 8 10 12 16 20 30 40 50 70 80 100 140 200

4.75 3.35 2.36 2.0 1.7 1.18 850 µ M 600 425 300 212 180 150 106 75

U.S.

MM

DECIMAL 0.187 0.132 .0937 .078 .066 .0469 .0331 .0234 .0165 .0117 .0083 .0070 .0059 .0041 .0029

90

80

70

60

50

40

30

20

10

0

0

10

20

30

40

50

60

70

80

90

100

PERC

ENT P

ASSIN

G PERCENT PASSING

FM AND SE

90

The factor called Fineness Modulus (FM) which iscommonly used, serves as a quick check that a givensample meets specifications without checking eachsieve size of material against the standards set for aparticular job. FM is determined by adding the cumu-lative retained percentages of sieve sizes #4, 8, 16,30, 50 and 100 and dividing the sum by 100.

Sieve % Passing % Retained#4 97 3#8 81 19#16 59 41#30 36 64#50 15 85#100 4 96

308 / 100 = 3.08 (FM)

Different agencies will require different limits on theFM. Normally, the FM must be between 2.3 and 3.1 forASTM C-33 concrete sand with only 0.1 variation for allthe material used throughout a certain project.

The Sand Equivalent Test (SE) is more complex thanthe FM test. The "equivalent" refers to the equivalentquantities of fine vs coarse particles in a given sandsample. The test is performed by selecting a givenquantity of a sand sample and mixing it in a specialsolution. The chemicals in the solution contain excel-lent wetting agents. These wetting agents will rapidlydissolve any deposits of semi-insoluble clays or plasticclays, which are clinging to the individual sand parti-cles. After a specified period of agitation, either byhand or by machine, the sample is allowed to stand ina graduated tube for a specified time period. Aweighted plunger is slowly lowered into the settledsand-solution mixture, and the depth to which theweight descends is noted from the graduations on thetube. A formula is supplied with the testing apparatus,and from that formula the "SE" is determined.

COARSE MATERIAL WASHING

In order to produce aggregate at the most economicalcost, it is important to remove as soon as possible fromthe flow of material any size fraction that can be con-sidered ready for use. The basic process consists ofcrushing oversize material, scrubbing or washing coat-ings or entrapped materials, sorting and dewatering.Beneficiation of some coarse aggregate fractions maybe necessary. When scrubbing or washing of coarsematerial is required, it is generally a consideration ofthe material size, the type of dirt, clay or foreign mate-rial to be scrubbed and the Tons Per Hour rate neededthat will determine the coarse material washing equip-ment to use.

91

In general, the finer the sand, the deeper the weightwill penetrate. The wetting agents, that dissolve theclay, make a seemingly coarse material much finerbecause the clays are now a separate, very fine prod-uct. This extra fine material acts as a lubricant and theweight will descend deeper in the sample. Because ofthis, it is possible that a sample with an acceptable FMis rejected for failure to pass the SE test.

Purpose: In the aggregate business the log washer isknown best for its ability to remove tough, plastic solu-ble clays from natural and crushed gravel, crushedstone and ore feeds. The log washer will also removecoatings from individual particles, break up agglomer-ations, and reduce some soft, unsound fractions by aform of differential grinding.

Design: The log washer consists of a trough or tank ofall welded construction set at an incline (typically 6-10°) to decrease the transport affect of the paddlesand to increase the mass weight against the paddles.Each “log” or shaft (two per unit) is fitted with four rowsof paddles which are staggered and timed to allow thepaddles of each shaft to overlap and mesh with thepaddles of the other shaft. The paddles are pitched toconvey the material up the incline of the trough to thedischarge end.

92

SERIES 8000 LOG WASHERS

Kolberg’s log washer design improves on the tradi-tional design in that the paddles are set in a spiralpattern around the shaft instead of in a straight line asin competitive units. This design feature providesmany benefits including: 1) Reduces intermittentshock loading of the log, 2) Keeps a portion of themass in motion at all times thus reducing power peaksand valleys as well as overall power requirements,3) Reduces wear and 4) Provides more effectivescrubbing. Other important features of the Kolberg logwasher include two (2) large tank drain/clean-outports, rising current inlet, overflow ports on each sideof the unit, cast ni-hard paddles with corrugated faces,readily available externally mounted lower end bear-ings and a custom designed and manufactured singleinput dual output gear reducer.

Application: The majority of the scrubbing action per-formed by the log washer is accomplished by theabrading action of one stone particle on another, not bythe action of the paddles on the material. Due to thisand other feed material characteristics such as claysolubility, the capacity of a log washer is given in afairly wide range. Normal practice is to follow the logwasher with a screening device on which spray barsare used to remove fines and clay coatings on thestone.

93

Water Maximum Approx. Approx.Capacity Motor Req’d. Feed Size Dead Load Live Load

Model (TPH) (HP) (GPM) (in.) (lbs.) (lbs.)

8024-18 25-60 40 25-250 3" 12,500 20,500

8036-30 85-125 100 50-500 4" 34,000 75,000

8048-30 125-225 150 100-800 5" 47,500 90,000

8048-35 125-225 200 100-800 5" 53,000 95,500

KOLBERG LOG WASHERS

SERIES 6000 COARSE MATERIAL WASHERS

94

Purpose: The coarse material washer is used toremove a limited amount of deleterious material from acoarse aggregate. This deleterious material includesshale, wood, coal, dirt, trash and some very solubleclay. A coarse material washer is often used as finalwash for coarse material (typically -21⁄2" x +3⁄8") follow-ing a wet screen. Both single and double spiral unitsare available depending on the capacity required.

Design: The coarse material washer consists of along vertical sided trough or tank of all welded con-struction set at a 15° incline. The shaft(s) or spiral(s)of a coarse material washer begin with one doublepitch spiral flight with replaceable ni-hard outer wearshoes and AR steel inner wear shoes. Following thissingle flight is a variable number of bolt-on paddleassemblies. Standard units include four (4) sets ofpaddle arms with ni-hard tips. Two (2) sets of armsreplace one full spiral. The balance of the spiral(s)consists of double pitch spiral flights with replaceableni-hard outer wear shoes and AR steel inner wearshoes.

Other important features of the Kolberg coarse mater-ial washer include a rising current manifold, adjustablefull width overflow weirs, readily available externallymounted lower end bearing(s) and upper end bear-ing(s) and shaft mounted gear reducer with v-belt driveassembly (one drive assembly per spiral).

Application: As previously noted, the number of pad-dle assemblies can be varied. The number of paddleassemblies installed on particular unit is dependent onthe amount of water turbulence and scrubbing actionrequired to suitably clean the feed material. As thenumber of paddles is increased, the operational char-acteristics of the unit change including increasedscrubbing action, increased retention time, reducedcapacity and increased power requirements.

95

Approx. Approx.Water Dead Live

Capacity Motor Req’d. Load LoadModel (TPH) (HP) (GPM) (lbs.) (lbs.)

SINGLE SPIRAL CONFIGURATIONS:

6024-15S 60-75 15 300-400 6,200 11,200

6036-19S 150-175 25 400-600 10,400 21,900

6048-23S 200-250 40 500-700 15,600 43,600

TWIN SPIRAL CONFIGURATIONS:

6036-19T 300-350 25 700-900 18,000 41,000

6048-23T 400-500 40 800-1000 27,920 81,000

NOTE: Two (2) motors required on twin units. 24" diameter unit offered onlyin single spiral configuration.

KOLBERG AGG PREPS

SERIES 6500 BLADEMILLS

96

Purpose: Similar in design to the Series 6000 CoarseMaterial Washer, the blademill is used to pre-conditionaggregates for more efficient wet screening. Blade-mills are generally used prior to a screening andwashing application to break up small amounts ofsoluble mud and clay. Typical feed to a blademill is21⁄2" x 0". Units are available in both single and doublespiral designs depending on the capacity required.

Design: The blademill consists of a long vertical sidedtrough or tank of all welded construction set at a vari-able incline (typically 0-4°) depending on the degree ofscrubbing or pre-conditioning required. The shaft(s) orspiral(s) of a blademill begin with one double pitch spi-ral flight with replaceable ni-hard outer wear shoes andAR steel inner wear shoes. Following this single flightis a combination of bolt-on paddle and flight assem-blies, which can be varied, depending on the amountof scrubbing required. The flight assemblies includereplaceable ni-hard outer wear shoes and AR steelinner wear shoes. The paddle assemblies are fittedwith replaceable cast ni-hard paddle tips. Other impor-tant features of the Kolberg blademill include readilyavailable externally mounted lower end bearing(s) andupper end bearing(s) and shaft mounted gear reducerwith v-belt drive assembly (one drive assembly perspiral).

Application: The number of paddle and flight assem-blies as well as the angle of operation can be varieddependent upon the amount of scrubbing or pre-con-ditioning required. Also, as the number of paddles orangle of operation is increased, the operational char-acteristics of the unit change including increasedscrubbing action, increased retention time, reducedcapacity and increased power requirements.

Capacities/Specifications: Blademill capacity is indi-rectly a function of retention time. Each application willindicate a required period of time for effective washing,which actually determines the capacity of the unit. Asa rule of thumb, a blademill can be expected toprocess in the range of a coarse material washer withrespect to raking capacity in TPH and requires approx-imately 1⁄4 to 1⁄3 of the water required in a coarsematerial washer. If sufficient information is not avail-able with regards to clay content and solubility, thelower end of the coarse material washer range shouldbe used. Kolberg blademills are offered in single ortwin screw configurations of the same size as coarsematerial washers.

97

FINE MATERIAL WASHINGAND CLASSIFYING

INTRODUCTION

Aside from washing sand to remove dirt and silt,hydraulic methods are employed to size the materialand to classify or separate it into the proper particledesignation. After these steps, it is usual procedure todewater the product.

Washing aggregates to clean them is not new. How-ever, much closer attention has been given to both thecleanliness and the gradation of the fines in construc-tion aggregates. Thus has developed a new "art" inthe processing of fine aggregates. This "art" requiresmore technical know-how and methods more precisethan those usually associated with the mere washingof gravel and rock. At the same time, it has been nec-essary to advance the art in a practical way so as toproduce material at a reasonable price.

Screening is the best way to separate coarse aggre-gates into size ranges. With fine materials, however,screening on less than No. 8 mesh usually is impracti-cal. This necessitates a split between 3⁄8" and #4 meshputting everything finer into the category of requiringhydraulic separation for best gradation control.

With hydraulic separation, a large amount of water isused. Here separation depends on the relative buoy-ancy’s of the grain particles and on their settling ratesunder specific conditions of water flow and turbulence.In some cases, separation depends on the relativespecific gravity difference between the materials to beseparated and the hydraulic medium. In a certainsense, this applies when water is used to separate par-ticle sizes of sands. Perhaps it would be more apt tosay this separation of sands is based on relative den-sities or that the process separates by gravity.

98

In its strictest sense, however, classifying means thatseveral sizes of sand products of equal specific grav-ity can be separated while rejecting slimes, silt, andsimilar deleterious substances. But sand particles arenot necessarily always of the same specific gravity, sofrequently both specific gravity and particle size affectthe rate of settling. As a consequence, you cannotalways estimate the probable gradation of the finalproducts without preliminary tests on the material. Norcan you be sure of product quality without analysis andtests after processing.

In any hydraulic classification of sand, the amount offines retained with the final product will be dependentupon:

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 willbe fixed. Hence the amount and size of fines to berejected will be determined by regulating the waterquantity and turbulence.

99

Purpose: Fine material washers, also frequentlycalled screw classifiers or screw dehydrators, are uti-lized to clean and dewater fine aggregates (typically–3⁄8" or -#4 mesh), fine tune end products to meet spec-ifications and to separate out slimes, dirt and fines(typically -#100 mesh or finer). Available in both singleand twin configurations, fine material washers aremost often used after a sand classifying/blending tankor after a wet screening operation.

Design: The fine material washer consists of an allwelded tub set at an incline of approx. 18.5° (4:12slope) and includes a full length curved bottom withintegral rising current manifold designed to controlfines retention and the water velocity within the pool.The lower end of the tub or tank is flared to provide alarge undisturbed pool, which provides accurate mate-rial classification. Long adjustable weirs around thetop of the sides and end of the tub’s flared portion aredesigned to handle large volumes of slurry and to con-trol the pool level for uniform overflow. Alsoincorporated into the design of the tub is a chase waterline to clear the drain trough for better dewatering andan overflow flume.

100

SERIES 5000 FINE MATERIAL WASHERS

The shaft(s) or spiral(s) of the fine material washerconsist of a double pitch, solid flight spiral completewith AR steel inner wear shoes and urethane outerwear shoes to provide protection of the entire flight(cast ni-hard outer wear shoes are optional). Otherimportant features of the Kolberg fine material washerinclude readily available externally mounted lower endbearing(s) and upper end bearing(s), shaft mountedgear reducer with v-belt drive assembly (one driveassembly per spiral) and center feed box with internaland external baffles to reduce the velocity of the mate-rial entering the fine material washer and reduce poolturbulence, enhancing fines retention.

Application: Two important elements must be con-sidered when sizing a fine material washer for aparticular application: 1) calculation of overflowcapacities and 2) calculation of sand raking capacity.Overflow capacity is critical to ensure that the unithas sufficient capacity to handle the water requiredfor proper dilution of the feed material which allowsfor proper settling to occur and to produce thedesired split point. The raking capacity of a finematerial washer is governed by the fineness of thematerial to be dewatered. Generally speaking, thefiner the material to be raked, the slower the spiralspeed must be to ensure adequate dewatering andreduced pool turbulence. The following tables areprovided to assist in the proper selection of a finematerial washer.

101

% SCREW SPEED % PASSING % PASSING % PASSING(RPM) 50 MESH 100 MESH 200 MESH

100% 15 2 0

75% 20 5 0

50% 30 10 3

25% 50 25 8

PERCENT SCREW SPEED vs. PERCENT FINES(in the product)

CAPACITY MINIMUM OVERFLOW CAPACITIESSINGLE/ % SCREW SPIRAL MOTOR HP (GPM)

TWIN SPEED SPEED REQ’D/ SINGLE/TWINMODEL (TPH) (RPM) (RPM) SPIRAL 100 MESH 150 MESH 200 MESH

50 100% 32 7.5*5024-25 37 75% 24 5 500 225 125

25 50% 16 512 25% 8 3

75 100% 25 10*5030-25 55 75% 19 10 550 275 150

38 50% 13 7.518 25% 7 5

100/200 100% 21 155036-25 75/150 75% 15 10 700/1200 325/600 175/300

50/100 50% 12 7.525/50 25% 6 5

175/350 100% 17 205044-32 130/260 75% 13 15 1500/2700 750/1300 400/750

85/170 50% 9 1045/90 25% 5 7.5

200/400 100% 16 205048-32 150/300 75% 12 15 1650/2900 825/1450 450/825

100/200 50% 8 1050/100 25% 4 7.5

250/500 100% 14 305054-34 185/370 75% 11 25 1800/3200 900/1600 525/900

125/250 50% 7 1560/120 25% 4 10

325/650 100% 13 305060-35 250/500 75% 9 25 2200/3600 1000/1800 550/950

165/330 50% 5 2085/170 25% 3 15

400/800 100% 11 405066-35 300/600 75% 8 30 2400/4000 1100/2000 625/1000

200/400 50% 5 25100/200 25% 3 15

475/950 100% 11 605072-38 355/710 75% 8 50 2600/4400 1250/2200 700/1200

235/475 50% 5 30120/240 25% 3 15

102

KOLBERG SAND PREPSRAKING & OVERFLOW CAPACITY TABLE

NOTE: Two (2) motors required on twin units. *24" & 30" dia. units offered only in single spiral configuration.

KOLBERG SAND PREP WEIR OVERFLOW RATES

103

NOTE: All flows shown are in gpm. Bold italicized flows depict overflow rates required for 200, 150 & 100 mesh splits respectively.

AVERAGE DEPTH OVER WEIRMODEL WEIR LENGTH 1⁄4" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 13⁄4" 2" 21⁄4" 21⁄2"

125 225 5005024-25S 15'3" 92 229 397 564 717 991 1205 1449 1678 1983

150 275 5505030-25S 15'9" 95 236 410 583 740 1024 1244 1496 1733 2048

175 325 7005036-25S 16'3" 98 244 423 601 764 1056 1284 1544 1788 2113

300 600 12005036-25T 19'9” 119 296 514 731 928 1284 1560 1876 2173 2568

400 750 15005044-32S 22'0" 132 330 572 814 1034 1430 1738 2090 2420 2860

750 1300 27005044-32T 26'0" 156 390 676 962 1222 1690 2054 2470 2860 3380

450 825 16505048-32S 22'3" 134 334 579 823 1046 1446 1758 2114 2448 2893

825 1450 29005048-32T 26'9" 160 401 696 990 1257 1739 2113 2541 2943 3478

525 900 18005054-34S 26'0" 156 390 676 962 1222 1690 2054 2470 2860 3380

900 1600 32005054-34T 31'0" 186 465 806 1147 1457 2015 2449 2945 3410 4030

550 1000 22005060-35S 26'6" 159 398 689 981 1246 1723 2094 2518 2915 3445

950 1800 36005060-35T 31'6" 189 473 819 1166 1481 2048 2489 2993 3465 4095

625 1100 24005066-35S 27'3" 164 409 709 1008 1281 1771 2153 2589 2998 3543

1000 2000 40005066-35T 32'9" 197 491 852 1212 1539 2129 2587 3111 3603 4258

700 1250 26005072-38S 27'9" 167 416 722 1027 1304 1804 2192 2636 3053 3608

1200 2200 44005072-38T 34'3" 206 514 891 1267 1610 2226 2706 3254 3768 4453

CLASSIFICATION METHODSAPPLIED TO FINE AGGREGATES

INTRODUCTION

Classification is the sizing of solid particles by meansof settling. In classification, the settling is controlled sothat the very fines, silts and clays will flow away with astream of the water or liquid, while the coarse particlesaccumulate in a settled mass.

Washing/classifying equipment is manufactured inmany different configurations depending on the naturalmaterial characteristics and the end product(s)desired. Although, the general definition of aggregateclassifying can be applied to coarse material (+3⁄8"), it ismost commonly applied to the material passing 3⁄8".Included in the fine material classifying equipment arethe sand screws, counter-current classifiers, sanddrags and rakes, hydro-cyclones, hydro-classifiers,bowl classifiers, hydro-separators, density separatorsand scalping/classifying tanks.

All the above mentioned classifiers except the scalp-ing/classifying tank are generally single productmachines which can only affect the gradation of theend product on the very fine side (the overflow sepa-ration size). This separation size, due to the mechani-cal means employed, is never a knife-edge separation.However, the aim of modern classification methods isto approach a clean-cut differentiation. Many materialspecifications today call for multiple sizing of sand withprovisions for blending back to obtain the gradationsrequired. It is rare to find the exact blend occurringnaturally or to economically manufacture the blend toexact specifications. In either case, the accepted pro-cedure is to screen out the fine material from which thesand specifications will be obtained. This material isprocessed in a water scalping/classifying tank for mul-tiple separation by grain sizes or particle specificgravity.

There is no mystery connected with classifying tanks.They are merely long settling basins capable of hold-ing large quantities of water. The water and sand mix

104

(slurry) is introduced into the tank at the feed end. Theslurry, which often comes from dredging or wet screen-ing operations, flows toward the overflow end, and asit does, solids settle to the bottom of the tank. Weightdifferences between sand particles allow coarsermaterial to settle first while lighter material progres-sively settles out further along the tank length.

PRINCIPLES OF SETTLING

The specific gravity of aggregates varies according tothe nature of the minerals in the rock. "Bulk" specificgravity is used in aggregate processing and indicatesthe relative weight of the rock or sand, including thenatural pores, voids and cavities, as compared towater (specific gravity = 1.0). In the case of fine aggre-gates, the specific gravity is about 2.65. As aconsequence, the weight of grains of sand will bedirectly proportional to their volume. All grains of sandof a given size will therefore weigh the same, and theweight can be measured in relation to the opening ofthe sizing sieve.

A second basic consideration is that of the density orspecific gravity of the slurry itself. Dilution is usuallyexpressed in percentages by weight of either the solid,or, of the water. Since the specific gravity of water is1.00 and that of sand is assumed to be 2.65, a simplecalculation will give the specific gravity, or density, ofthe slurry mixture.

CALCULATION OF SLURRY OR PULP

105

The following method of calculating slurry or pulp isquick, accurate and requires no reference tables. Itmay be used for any liquid-solid mixture.

Basic equation, for a single substance or mixture:

GPM = TPH x SG

For Water: GPM Water = TPH Water x 4

For Solids: GPM Solids = TPH Solids x SG Solids

4

4

For Solids SG 2.65-2.70 (sand, gravel, quartz, lime-stone): GPM Solids = TPH Solids x 1.5

For Slurry: GPM Slurry = TPH Slurry x SG Slurry

To solve for Specific Gravity:

SG Slurry = GPM Slurry

Example:Given: 10 TPH of Sand @ 40% Solids (by weight)Find: GPM and SG of SlurryUse this matrix to calculate your data

106

4

TPH Slurry x 4

% Weight TPH SG GPM

Water 1.0

Solids 40 10 2.67

Slurry 100

% Weight TPH SG GPM

Water 60 15 1.0 60

Solids 40 10 2.67 15

Slurry 100 25 1.33 75

Fill in as follows:1) Convert % Weight to decimel form: 40% = 0.402) TPH Slurry = TPH solids divided by 0.40 = 253) TPH Water = TPH Slurry - TPH Solids = 154) GPM Water = TPH Water x 4 = 605) GPM Solids = TPH Solids x 1.5 = 156) GPM Slurry = GPM Water + GPM Solids = 757) SG Slurry = TPH Slurry x 4/GPM Slurry = 1.33

The tablulation can be solved for all unknowns if SGSolids and two other principal quantities are given.

If GPM Slurry, % Solids and SG Solids are given, solvefor 1 TPH and divide total GPM Slurry by resultantGPM Slurry to obtain TPH Solids.

Rework tabulation with this figure to check the result.

Percent Solids by Volume may be calculated directlyfrom GPM column.

GPM column may also be extended to any other unitdesired; 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 inher-ent in given quantities.

3) For sea water, use SG 1.026. In this case, the differenceis appreciable.

107

CONVERSION FACTORSTo Obtain Multiply By Based OnTPH Cu. Yd/Hr. 1.35 Sand 100#/cu. ft., dry.Short TPH Long TPH 1.12 2240 lb. tonShort TPH Metric TPH 1.1023 Kilo = 2.2046 lb.U.S. GPM British GPM 1.201U.S. GPM Cu. Ft./Min. 7.48U.S. GPM Cu. Ft./Sec. 448.5

The third consideration is that of viscosity. Viscositycan be compared to friction in that it is a resistance tomovement between liquid particles and between solidand liquid particles.

In a continuous process, such as in the production offine aggregates, the slurry flows into and out of theclassifying tank at a measurable rate, which deter-mines its velocity of flow through the tank. The solidssettle out, due to their weight, at a speed that isexpressed as rate of fall or settling. It is the interrela-tionship between these two movements which governsthe path of the falling particle.

GA

LA LB LC LD LE

B C

OVERFLOW

PATH OF PARTICLE

HORIZONTAL TRAVEL OF FALLING SAND PARTICLES

DIAGRAM OF FORCES

D

Settling From A Surface Current

D

FEED

E

VO

In the figure above, directions of the current and of the free fall of the particleare at right angles. The actual path of a falling particle is a parabola; theheight of fall (D) and the length of horizontal travel (L) are determined by useof well-known formula. This is called settling from a surface current.

While a particle is in suspension, one force acts on it tomake it fall, while others act to retard the fall. The forcethat acts downward is that of gravity (g). It has beenbrought out that viscosity of the liquid may retard thefall. The difference between free settling and hinderedsettling is a relative one between the factors causing aparticle to fall and those retarding the fall. In free set-tling the downward component is much greater thanthose slowing up the fall are. In hindered settling thedownward component is only slightly greater thanthose slowing the fall are.

Apart from the multiple sizing, the scalping tank servesto eliminate the surplus water prior to discharge ofproduct to a screw-type classifier. By so doing, theamount of water handled by the screw classifier can beregulated better for the mesh size of fines to beretained. It becomes apparent, then, that a waterscalping tank will be followed by as many screw clas-sifiers as there are sizes of sand products to be made.

Adjustable weirs on the scalping tank regulate the rateand velocity of overflow to provide the size separationsrequired. Clays, silt and slime which are lighter thanthe finest mesh sand, remain suspended in the waterand are washed out over the tank weirs for dischargeinto a settling pond.

In order to re-blend sand fractions into a specificationproduct, settling stations are located along the bottomlength of the tank. The best classifying occurs withmore length to the classifying tank. It is recommendedto use a minimum of a 28' tank. Shorter tanks will workwhen the material is very consistent in gradation andclose to the product specification to be made.

Build up or "silting in" of the classifying tank will occuras the specific gravity of the overflow slurry goesbeyond 1.065. The ideal slurry is between 1.025 and1.030. At this point maximum efficiency occurs. Addi-tional water will carry away more fines unless the tankarea is oversized.

108

109

0 10 20 30 40 50 60 70 80

0 10 20 30 40 50 60 70 80

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

SP

EC

IFIC

GR

AV

ITY

SL

UR

RY

OR

PU

LP

(G

)

SP

EC

IFIC

GR

AV

ITY

SL

UR

RY

OR

PU

LP

(G

)

DENSITY PERCENT SOLIDS

DENSITY PERCENT SOLIDS

G=

=

1000WT 1 LITER SLURRY IN GRAMS

DENSITY % SOLIDS BY WEIGHT

G160 (G-1)

=DENSITY % SOLIDS BY VOLUME

60 (G-1)

FOR THE ABOVE MATERIALS

FOR G = 1.25

DENSITY = 32% SOLIDS BY WT

OR 15% SOLIDS BY VOL

EXAMPLE

FOR

SO

LID

S B

Y W

EIG

HT

FOR

SO

LID

S B

Y VO

LUM

E

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.

DENSITY—SPECIFIC GRAVITY RELATIONSHIPFOR WATER SLURRY OF SAND, GRAVEL,

QUARTZ OR LIMESTONE(SOLID S.G. 2.65-2.70)

110

SERIES 7000 SAND CLASSIFYING TANKS

Purpose: Classification is the sizing of solid particles(typically –3⁄8" or -#4 mesh) by means of settling. Inclassification, the settling is controlled so that the finesor undersize material will flow away with a stream ofwater or liquid, while the coarse or oversize materialaccumulates in a settled mass. By applying the princi-ples of settling and classification in the classifying/water scalping tank, the following functions are per-formed: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 asand and water slurry. The slurry feed can come fromseveral sources, but is generally from a dredging orwet screening operation.

CLASSIFYING TANKS ARE NECESSARY WHEN ANY ONE OF THE FOLLOWING CONDITIONS EXIST:

1) Feed material gradations fail to meet the allowableminimums or maximums when compared to thematerial 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.

Design: A classifying tank consists of an all weldedtank of varying size ranging from 8' x 20' to 12' x 48'.The slurry feed is introduced into the tank through afeed box, which includes an integral curved liner forimproved slurry flow control. As the slurry flows towardthe discharge end of the tank, weight differencesbetween sand particles allow coarser material to settlefirst while the lighter material settles progressively fur-ther down the tank. Clays, silt and slime which arelighter than the finest mesh sand remain suspended inthe water and are washed out over the adjustable tankweirs for discharge into a settling pond. Sand fractionsare then reblended into two specification products andan excess product, via settling stations (six to elevendepending on tank length) located along the bottom ofthe tank. Discharge valves (typically three) at eachstation serve to “batch” the sand into a collecting/blending flume located below the tank.

111

Coarse Medium

FEED

A BC

VELOCITY CLASSIFICATION

Fine Very Fine

Water andSlime

Sand discharge is controlled via a controller (see sec-tion on Kolberg Spec-Select™ Classifying TankControllers) which receives a signal from an adjustableheight sensing paddle located at each station. Thesensing paddle controls the amount of material thataccumulates at each station before a valve opens todischarge the sand and water slurry. The valves con-sist of self-aligning urethane dart valves and urethaneseats providing uniform flow at the maximum rate, pos-itive sealing and long service life. The urethane dartvalve is connected to an adjustable down rod to ensureoptimum seating pressure and provide leak resistantoperation. The valves are activated by an electric/hydraulic mechanism in response to signals receivedfrom the controller and sensing paddle. Once dis-charged, the slurry flows through product down pipes,which include urethane elbows for improved flow andwear into a collecting/blending flume for transport tothe appropriate dewatering screw.

The electric/hydraulic mecha-nism is mounted within abridge that runs lengthwisewith the tank. This systemincludes an electric/hydraulicpump, reservoir, accumulator,individual ball and check valvesat each station and a toggleswitch box with 3-positionswitch for each individualvalve providing maximumflexibility in trouble shootingand servicing the classifyingtank. Other important featuresof the Kolberg classifying tankinclude stainless steelhydraulic tubing with O-ringface seal fittings, optional ris-

ing current cells to create hindered settling, optionalrecirculating pump to reduce overall water require-ments and complete pre-wiring of the tank to a NEMA4 junction box located near the end of the bridge.

112

AB

C

Application: Several factors affect the sizing andapplication of a classifying tank. Among these are drymaterial feed rate, material density, feed gradation,product gradations or specifications desired, feedsource, the amount of water entering the tank with thefeed material and other material characteristics suchas whether the material is crushed or natural. Of thesefactors, four items must be known to properly size aclassifying tank:• Feed rate (TPH)?• Feed gradation?• Feed source?…..Conveyor? Dredge?• Product gradations or specifications desired?

Given the above, the classifying tank is sized based onits water handling capacity. The requirements forwater in a classifying tank are to have approximately10 GPM of water for every 1 TPH of total sand feed or100 GPM of water for every 1 TPH of silt (-#200 mesh).The larger of these two figures and the desired meshsplit to be produced within the tank are then used tosize the classifying tank. This process allows forproper dilution of the sand so that the material will cor-rectly settle in the tank for proper classification. Thefollowing table is provided to assist in the proper selec-tion of a classifying tank.

113

APPROX. APPROX. NUMBERDEAD LIVE OFLOAD LOAD WATER CAPACITIES (GPM) DISCHARGE

SIZE (LBS) (LBS) 100 MESH 150 MESH 200 MESH STATIONS

8' X 20' 9,600 61,000 2300 1200 700 6

8' X 24' 11,800 73,000 2800 1400 800 7

8' X 28' 14,000 86,800 3200 1600 900 8

8' X 32' 16,300 99,600 3500 1800 950 9

10' X 24' 16,000 125,000 3500 1800 950 7

10' X 28' 18,000 145,000 4100 2100 1100 8

10' X 32' 21,000 160,000 4700 2400 1250 9

10' X 36' 24,000 180,000 5300 2700 1400 10

10' X 40' 27,000 200,000 5900 3000 1550 11

12' X 48' 39,000 270,000 8100 4200 2150 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.

KOLBERG SAND SORTS

114 KOLBERG SAND SORT WEIR OVERFLOW RATES

NOTE: All flows shown are in gpm. Bold italicized flows depict overflow rates required for 200, 150 & 100 mesh splits respectively.

AVERAGE DEPTH OVER WEIRMODEL WEIR LENGTH 1⁄4" 1⁄2" 3⁄4" 1" 11⁄4" 11⁄2" 13⁄4" 2" 21⁄4"

700 1200 23008' x 20' 32' 225 480 800 1150 1690 2225 2720 3360 4400

800 1400 28008' x 24' 40' 280 600 1000 1440 2120 2800 3400 4200 5000

900 1600 32008' x 28' 48' 336 720 1200 1720 2550 3350 4070 5040 6000

950 1800 35008' x 32' 56' 392 840 1400 2010 2960 3920 4750 5880 7000

950 1800 350010' x 24' 42' 295 630 1050 1520 2230 2940 3570 4400 5250

1100 2100 410010' x 28' 50' 350 750 1250 1800 2650 3500 4250 5240 6250

1250 2400 470010' x 32' 58' 410 880 1450 2080 3060 4060 4930 6080 7250

1400 2700 530010' x 36' 66' 465 990 1650 2380 3500 4630 5610 6920 8250

1550 3000 590010' x 40' 74' 520 1110 1850 2660 3920 5180 6290 7760 9250

2150 4200 810012' x 48' 80' 562 1200 2000 2876 4238 5600 6800 8390 10000

Purpose: Kolberg Spec-Select™ controllers areutilized in conjunc-tion with aclassifying tankto control theblending of thevarious sandfractions intoone or two spec-ification productsplus an excessproduct. Spec-Select™ controllers are also a valuablesource of information when trouble shooting or simplymonitoring the activity occurring within a classifyingtank.

Design: Spec-Select™ controllers consist of anindustrial quality solid-state PLC (Programmable LogicController) and/or PC (Personal Computer) housed ina NEMA 4 enclosure. Simple, touch-screen controlsare used on all systems for the operator to set andadjust the electronic timers, proportioning the amountof material to be discharged from the three valves ateach station of the classifying tank. EEPROM memoryprovides permanent storage of the screens in the dis-play unit, which are used to create a user-friendlyinterface to the PLC, which actually controls the tank.

Application: Two modes of controlling the tank dis-charge are utilized in conventional classifying tanks.The Spec-Seclect™ I (SSI) mode of operation is thesimplest method to operate a classifying tank and isthe same in theory as the manual splitter box typeclassifying tanks. It is an independent control of eachstation by a percentage method to determine theamount of material discharged to each of the threeproduct flumes. The system operates on a 10-secondcycle that is repeated over and over from product “A”to “B” to “C”. The mode of operation works best in afairly consistent pit where the feed gradation does notvary too much. Monitoring of the product gradationsinforms the operator of variances in the feed. Changesto the percentage settings at each station can be madequickly at the controller to maintain the product speci-fication. 115

SPEC-SELECT™ CONTROLLERS

The Spec-Select™ II (SSII) mode of operation is adependent method of operation utilizing minimum andmaximum timer settings at each station to control thematerial discharge and ensure that product specifica-tions are met on a consistent basis. This system notonly controls the discharge valves at each station butalso controls all of the settling stations relative to eachother. The minimum and maximum timer settings aredetermined by the gradation of the material settling outat each station and relating this to the product specifi-cation limits. In effect, the SSII mode of operation ismaking batches of specification sand continuously.Each “A” or “B” valve at a given station dischargessand on a time basis between its minimum and maxi-mum timer settings. No valve can begin a new batchuntil every other valve has discharged at least its min-imum in the present batch being made. When a valvereaches its maximum timer setting and one or more ofthe other valves for that product have not yet met theirminimum settings, the controller automatically directsthe material to one of the other product valves andflumes. It is important to remember, in this mode ofoperation, the potential to waste or to direct sand to anon-spec product where it is not desired is increasedand should be carefully considered when operating atank by this method. This mode of operation is typi-cally used when the feed gradation and/or feed ratevary widely.

KOLBERG OFFERS THREE MODELS OF SPEC-SELECT™ CLASSIFYING TANK CONTROLLERS:

116

NOTE: Each controller upgrade (i.e. – SSI >>, SSII >>, SSIII) alsoincorporates additional feedback or monitoring screens to assist theoperator in fine tuning the control of the classifying tank discharge.

Spec-Select™ I Spec-Select™ II Spec-Select™ III

Mode of Operation SSI SSI & SSII SSI & SSIITouch Screen Monochrome Monochrome ColorOperator Interface PLC PLC PC

operator interfacewith PLC control

Printer Compatible Yes Yes Yes

Disc Download – No No Yes Optional

Modem Hook-up – No No YesOptional

NOTES:

117

Purpose: Screening/washing plants are utilized torinse and size up to three stone products while simul-taneously washing, dewatering and fine tuning a singlesand product. Specific stone product gradations cantypically be met with the use of blending gatesbetween the screen overs chutes while sand productgradations are adjusted with screw speed and wateroverflow rates.

Design: Series 1800 screening/washing plants con-sist of a heavy duty Kolberg-Pioneer two or three deck,10° wet screen (horizontal optional) mounted above aKolberg fine material washer on either a semi-portableskid support structure or a heavy duty portable chas-sis. Important features of the Kolberg screening/washing plant include the capability to fit three radialstacking conveyors under the screen overs chutes,complete water plumbing with single inlet connectionand wide three sided screen access platform as wellas all the features of the industry leading Pioneerscreen and Kolberg fine material washer.

Application: Review of the feed material gradation,products desired and TPH to be processed will deter-mine the screen and screw combination best suited forthe application.

118

SERIES 1800 SCREENING/WASHING PLANTS

Description Model 1814 Model 1822 Model 1830

Screen Size (triple deck, 10°) 5' x 14' 6' x 16' 6' x 20' Optional JCI Horizontal 6' x 16' 6' x 20'

Fine Material Washer Size 36" single 36" twin 44" twin

Fine Material Washer Capacity (@ 100% screw speed) 100 TPH 200 TPH 350 TPH

Water Requirements (up to maximum, dependent 700 GPM 1,200 GPM 2,700 GPMon feed material gradation)

OPTIONAL EQUIPMENT:

Skid Frame vs. Portable Chassis Yes Yes Yes

Feed/Slurry Box Yes Yes Yes

Wear Liners Yes Yes Yes

Screen Cloth Yes Yes Yes

Wedge Bolts (for screen cloth retention) Yes Yes Yes

Hydraulic Screen Adjust(portable plants only) N/A Yes Yes

Quickstop (screen) Yes Yes Yes

Electrical Package Yes Yes Yes

Horizontal Screen N/A Yes Yes

119

NOTE: Skid plants can be configured to include a number of different screenand screw combinations. For further capacity or specificationinformation on Kolberg-Pioneer screens and fine material washers,see the corresponding sections of this book relating to these pieces ofequipment.

KOLBERG 1800 SERIESSCREENING/WASHING PLANTS

JCI SCREENING THEORY

120

Screening is defined as a mechanical process whichaccomplishes a separation of particles on the basis ofsize. Particles are presented to a multitude of aper-tures in a screening surface and rejected if larger thanthe opening, or accepted and passed through ifsmaller. The material requiring separation, the feed, isdelivered to one end of the screening surface. Assum-ing that the openings in the screening media are all thesame size, movement of the material across the sur-face will produce two products. The material rejectedby 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, itcould come into contact with the solid wire or plate thatmakes up the screen media, or pass completelythrough the open hole. If the size of the particle is rel-atively small when compared to the openings, there isa high degree of probability that it will pass through oneof them before it reaches the end of the screen. Con-versely, when the particle is relatively large, or close tothe same size as the opening, there is a high degree ofprobability that it will pass over the entire screen andbe rejected to the overs. If the movement of the parti-cle is very rapid, it might bounce from wire to wire andnever reach a aperture for sizing. The velocity of theparticle, the incline of the screen, and the thickness ofthe wire all tend to reduce the effective dimensions ofthe openings and make accurate sizing more difficult.It becomes apparent that this simplified screen wouldperform much better if the following conditions pre-vailed:

1. Each particle is delivered individually to an aper-ture.

2. The particle arrives at the opening with zero forwardvelocity.

3. The particle traveled normal to the screen surface.4. The smallest dimension of the particle was cen-

tered on the opening.5. Screening surface has little or no thickness.

As material flows over a vibrating screening surface, ittends to develop fluid-like characteristics. The largerparticles rise to the top while the smaller particles siftthrough the voids and find their way to the bottom ofthe material bed. This phenomenon of differentiation iscalled stratification. Without stratification of the mate-rial, there would be no opportunity for the smallparticles to get to the bottom of the material bed andpass through the screen apertures causing separationof material by size.

After the material has been stratified to allow the pas-sage of throughs, the apertures are then blocked withoversize particles that were above the fines in thematerial bed before passage of more fines can occur,the bed must be restratified so the fines are again atthe bottom of the bed and available for passage. Thusthe process must be repeated successively until allfines are passed.

Potential occurrences that can prevent successfulscreening include:1. The arrival of several particles at an aperture, with

the result that none succeed in passing eventhough all are under-size.

2. Oversize particlesplugging the open-ings so thatundersize cannotpass though.

3. Undersize particlesblinding the aper-tures by sticking tothe screening mediawhich reduces theopening thus pre-venting passage ofundersize particles.

4. Oblique impact ofnear-size particlesbouncing off thesides of the aperturereducing efficiency.

121Figure 1

ELLIPTICAL STROKE FLAT SCREENSThe elliptical stroke flat screen combines the efficiencyof a horizontal with the tumbling action of a circularstoke incline screen. Figure 1 illustrates how the ellip-tical 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 tochange the angle of throw (timing angle), amplitude ofthrow (stroke length), and speed (RPM) of the screenallows the screen to be fine-tuned to maximize pro-duction. The bearing mounting method provides longservice life due to the outer ring rotation, which distrib-utes the loads over a larger area than conventionalinner race rotation designs.

The variations in the stroke patterns of Incline and Hor-izontal Screens are illustrated in Figure 1.

The elliptical stroke JCI screen with a 3⁄4" stroke run at875 RPM produces 8 G’s of acceleration to the vibrat-ing basket. This aggressive vibration helps preventdamp sticky material from adhering to the wirecloth,reducing the effective opening.

The stroke angle can be changed in 5 degree incre-ments from 30 to 60 degrees of inclination. Thisfeature allows the operator to change from a relativelyflat angle that results in a relatively high material veloc-ity across the screen, to more vertical angle that keepsthe material on the screen longer to allow the fines andnear size more time to find and pass through thescreen opening.

The operating speed of the JCI flat screen can be eas-ily changed with the factory supplied adjustable speedsheave. The removable shims in the sheave effec-tively change the pitch diameter of the drive sheave tovary the screen speed from 740 rpm to 875 rpm.

General guidelines for setting the operational parame-ters on the JCI flat screen are given in Figure 2. Ingeneral, coarse screening uses a large amplitude,slow speed, flat timing angle. As the Material to bescreened becomes finer, the amplitude gets smaller,the speed is increased, and the timing angle is steeperfor best results.

122

DAMP STICKY MATERIALThe adjustment features of the JCI flat screen, speed,stroke, and timing angle, can effectively be used tomaximize screen efficiency. Screen surface pluggingand blinding reduces the open area of the screenmedia thereby severely reducing efficiency. In plug-ging, the apertures in the screening media are pluggedby the wedging of particles in the openings, usually thishappens when there is a large amount of near-size,material passing over the screen. In blinding, under-size particles adhere to the screen structure and thento 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 becomesticky.

There are several solutions to the plugging blindingproblem. The simplest is to adjust the speed, strokelength, and inclination angle of the vibrating screen. Avigorous motion with a large stroke lifts the near-sizeparticles out of the openings and moves them alongthe surface of the screen media. The high g-forceacceleration associated with the JCI flat screen accel-erates the screen away from the material faster thangravity causes the material particles to free-fall. Thisaction effectively prevents plugging that can affect theefficiency of short stroke horizontal screens. Theaggressive vibration simultaneously shakes the cling-ing particles loose from the screen media and passesthem on to the throughs material and minimize theblinding of the screen surface. The JCI flat screenallows the operator to adjust the speed, stroke lengthand stroke inclination to minimize the effect of pluggingand blinding. If the material characteristics change,the operating parameters can be changed to optimizethe screening efficiency with changing material char-acteristics.

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 mate-rial sticks to the panel the mass increases to a pointwere the sticky material crumbles and is flung offthe screening media.

123

2. Adding a spray system to increase the moister con-tent of the material being screened. The waterbreaks down the fine material and flushes the finesthough the screening media.

3. The use of slotted opening wire to increase percentof open area and reduce the number of wires whichmaterial can build up on. The slots also increasethe distance material has to bridge before blindingoccurs in one direction.

4. End-tension decks also increase the percent ofopen area in two ways. The wire itself has greateropen area with fewer cross wires. The deck framehas fewer rails supporting the wire which blocksopenings reducing open area. End-tension wirehas a higher tension smaller diameter wire whichcuts through sticky material. End-tension wiresalso can flex independently between cross wiresvibrating like guitar strings preventing material fromsticking to the wire.

5. Z-wire also has increased open area over standardweave wire. As material sticks to the wire the massincreases to a point were defection of the wirecauses the sticky material to crumble and separatefrom the wire.

124

125

Size of Plug RPM of TimingMaterial Configuration Screen AngleCoarse 3 Plugs Each Wheel Very Slow

11⁄4" Plus 3⁄4" Approximately 740 RPM 45° - 55°Slow

Medium 2 Plugs Each Wheel 3⁄4" to 11⁄4" 40° - 50°3⁄4" - 11⁄4" 11/16" Approximately 785 RPM

FastFine 1 Plug Each Wheel 3⁄4" to 11⁄4" 35° - 45°

3⁄4" - 11⁄4" 5⁄8" Approximately 830 RPMNo Plugs Each Wheel

Extra Fine 9⁄16" Approximately Very Fast 30° - 40°3⁄8" Minus Minimum Stroke 875 RPM

GUIDELINES FOR STROKE ADJUSTMENTS

Fig

ure

2

126

SPRAY PIPE DESIGNAMOUNT 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 PipeDual Flat Spray PatternStandard Orifice Size 1/4"

Splash Spray PipeSingle Flat Splash Pattern3/16" Diameter Holes on 2" Centers

8203-38 6 6 5 17 425 3017 3655 42508202-38 6 - 5 11 275 1952 2365 27507203-38 6 6 5 17 374 2655 3216 37407202-38 6 - 5 11 242 1718 2081 24206203-32 6 6 5 17 323 2293 2778 32306202-32 6 - 5 11 209 1484 1797 20906163-32 5 5 4 14 266 1889 2288 26606162-32 5 - 4 9 171 1214 1471 17105163-26 5 5 4 14 210 1491 1806 21005162-26 5 - 4 9 135 959 1161 13505143-24 4 4 4 12 180 1278 1548 18005142-24 4 - 4 8 120 852 1032 1200

TOTAL TOTAL GAL. PER GAL. PER GAL. PERPIPES/DECK PIPES NOZZLES SCREEN SCREEN SCREEN

SCREEN PER PER AT 20 PSI AT 30 PSI AT 40 PSIMODEL TOP CTR BT SCREEN SCREEN 1⁄4" ORIFICE 1⁄4" ORIFICE 1⁄4" ORIFICE

STANDARD NOZZLE ORIFICE SIZE 1⁄4"20 PSI at Nozzle capacity is 7.1 gallons per minute30 PSI at Nozzle capacity is 8.6 gallons perminute40 PSI at Nozzle capacity is 10 gallons per minute

8' Spray Pipe has 25 Nozzles per pipe7' Spray Pipe has 22 Nozzles per pipe6' Spray Pipe has 19 Nozzles per pipe5' Spray Pipe has 15 Nozzles per pipe

SPLASH SPRAY PIPES

Approximately the same capacity as Nozzle Spray Pipes Shown above.

NOTES:

127

JCI Horizontal Screens are of a triple shaft design thatprovides a true oval vibrating motion, and feature ahuck-bolted basket assembly, fully contained lubrica-tion system, and rubber springs to reduce basketstress. Their low profile height makes them ideal forportability, and their adjustment capabilities of speed,stroke length, and stroke angle enable them to be wellsuited for both fine and coarse screening applications.JCI horizontal screens can be retrofitted with eitherwire cloth or urethane panels, and can be easily con-verted to wet screen applications.

JCI Horizontalscreens areavailable inseveral configu-rations in sizesranging from5x14 up to8x20 in bothtwo and threedeck designs.

128

JCI HORIZONTAL OVAL MOTIONVIBRATING SCREENS

FINISHING SCREENSThe JCI finishing screen maximizes screening efficiency and produc-tivity in fine separation applications by utilizing a reduced stroke and ahigher frequency that provides an optimal sifting action.

Adjustable stroke length (Amplitude) min 3⁄8" to max 1⁄2"(Stroke reduced by removing weight plugs.)

Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 875-1075 rpmMaximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 8"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . All model screens = 2"Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . 24"Cloth support bar thickness (Rail thickness) . . . . . . . 3⁄8"Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24"Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1⁄4"Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 5' & 6' = 5⁄16"

7' = 1⁄4"Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . 1⁄4"Discharge lip liner thickness (AR plate) . . . . . . . . . . . 1⁄4"Bearing size: 5142-24FS & 5143-24FS . . . . . . . . . . . . 120 mm

5162-26FS & 5163-26FS. . . . . . . . . . . . 130 mm6162-32FS & 6163-32FS. . . . . . . . . . . . 160 mm6202-32FS & 6203-32FS. . . . . . . . . . . . 160 mm7202-38FS & 7203-38FS. . . . . . . . . . . . 190 mm8202-38FS & 8203-38FS. . . . . . . . . . . . 190 mm

PATENT APPLIED FOR

129

STANDARD SCREENSThe standard series are best suited for the widestarray of applications ranging from fine to coarse mate-rial separation applications.

Adjustable stroke length (Amplitude) . . . . . . . . . . . . . min 5⁄8" to max 3⁄4"(Stroke reduced by removing weight plugs.)

Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 675-875 rpmMaximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 10"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . 514, 516 & 616 = 5"

620, 720 & 820 = 4"Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . 18"Cloth support bar thickness (Rail thickness) . . . . . . . 3⁄8"Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24"Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1⁄4"Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 1⁄4"Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . 1⁄4"Discharge lip liner thickness (AR plate) . . . . . . . . . . . 1⁄4"Bearing size: 5142-24 & 5143-24 . . . . . . . . . . . . . . . . 120 mm

5162-26 & 5163-26. . . . . . . . . . . . . . . . 130 mm6162-32 & 6163-32. . . . . . . . . . . . . . . . 160 mm6202-32 & 6203-32. . . . . . . . . . . . . . . . 160 mm7202-38 & 7203-38. . . . . . . . . . . . . . . . 190 mm6202-32LP & 6203-32LP . . . . . . . . . . . 160 mm7202-38LP & 7203-38LP . . . . . . . . . . . 190 mm8202-38W & 8203-38W . . . . . . . . . . . . 190 mm wide profile

PATENT APPLIED FOR

130

Adjustable stroke length (Amplitude) . . . . . . . . . . . . . min 9⁄16" to max 3⁄4"Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 675-875 rpmMaximum feed size* . . . . . . . . . . . . . . . . . . . . . . . . . . 14"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . All model screens = 5"Maximum drop of feed* . . . . . . . . . . . . . . . . . . . . . . . 16"Cloth support bar thickness . . . . . . . . . . . . . . . . . . . . 3⁄8"Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24"Top deck cross-member spacing . . . . . . . . . . . . . . . . 5': 6" WF 6': 8" WFSide Plate thickness* . . . . . . . . . . . . . . . . . . . . . . . . . 5⁄16"Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 5⁄16"Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . 1⁄4"Discharge lip liner thickness (AR plate) . . . . . . . . . . . 3⁄8" on 4" to 24" lipsBearing size: 5142-24 & 5143-24 . . . . . . . . . . . . . . . . 120 mm

5162-26 & 5163-26. . . . . . . . . . . . . . . . 130 mm6162-32MS . . . . . . . . . . . . . . . . . . . . . . 160 mm6202-32MS . . . . . . . . . . . . . . . . . . . . . . 160 mm7202-38 & 7203-38. . . . . . . . . . . . . . . . 190 mm

MEDIUM SCALPER SCREENSThe medium scalper screen is an excellent machinefor coarse screening and light duty scalping applica-tions, by implementing a slightly lower frequency andmore aggressive stroke length as compared to thestandard series. Medium scalper screens also featurea heavier duty construction for up to 14" feed.

PATENT APPLIED FOR

131

HEAVY SCALPER SCREENSThe heavy scalper two-deck screens are designed forheavy duty scalping applications, by implementing thelowest frequency and most aggressive stroke length inthe family of JCI horizontal screens. Heavy scalperscreens also feature the heaviest duty constructionthat can accept up to 18" feed sizes.

Adjustable stroke length* (Amplitude) . . . . . . . . . . . . min 3⁄4" to max 7⁄8"(Stroke reduced by removing weight plugs.)

Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range* . . . . . . . . . . . . . . . . . . . . . . . 575-775 rpmMaximum feed size* . . . . . . . . . . . . . . . . . . . . . . . . . . 18"Maximum top deck opening* . . . . . . . . . . . . . . . . . . . All model screens = 6"Maximum drop of feed* . . . . . . . . . . . . . . . . . . . . . . . 12"Cloth support bar thickness

(Rail thickness bottom deck) . . . . . . . . . . . . . . . . . 3⁄8"Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24"Top deck cross-member spacing . . . . . . . . . . . . . . . . 5': 8 WF 6': 10 WFSide Plate thickness* . . . . . . . . . . . . . . . . . . . . . . . . . 5⁄16"Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 5⁄16"Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . 1⁄4"Discharge lip liner thickness (AR plate) . . . . . . . . . . . 3⁄8" on 4" to 24" lipsBearing size: 5142-26HS . . . . . . . . . . . . . . . . . . . . . . 130 mm

5162-32HS . . . . . . . . . . . . . . . . . . . . . . 160 mm6162-38HS . . . . . . . . . . . . . . . . . . . . . . 190 mm

PATENT APPLIED FOR

132

LOW INCLINED SCREENSFor those producers who prefer the classic horizontalscreen design, JCI also manufactures a full line of 21⁄2°inclined screens. Contact the factory for additionalinformation on available sizes and models.

SPECIAL SCREEN DESIGNSJCI also provides several special designs includingclassic models for installation on Model 1145 and 1213ElJay cone/screening plants, screens designed withadditional clearance under the shaft tubes, and specialversions featuring special sloped decks, step decks,split crown rails, etc. Contact the factory for additionalinformation on all available models and sizes.

PATENT APPLIED FOR

PATENT APPLIED FOR

NOTES:

133

134

JCI incline screens feature HD side and reinforcingplates, huck bolted construction, an adjustable operat-ing incline from 15-25 degrees, adjustable strokeamplitudes, AR lined feed boxes, and HD double-rollbronze cage spherical roller bearings.

JCI incline screens are available in both single anddual shaft arrangements, two and three deck configu-rations, and are available in sizes ranging from 6x20up to 8x20.

JCI INCLINED SCREENS

JCI SINGLE SHAFT INCLINED SCREENSJCI single shaft incline screens are well suited for stationary installa-tions, for applications where the feed gradation to the screen isconstant, or when a circular stroke pattern will provide the desiredresults. Incline screens also enable a lower bed depth of material dueto an increased material travel speed. to minimize power consumptionwhile maximizing access for maintenance

Standard stroke length (Amplitude) . . . . . . . . . . . . . . 3⁄8" strokeStandard operating speed. . . . . . . . . . . . . . . . . . . . . . 800 rpmOptional stroke and speed relationships . . . . . . . . . . .

Maximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 8"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . 2"Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . 18"Cloth support bar thickness (Rail thickness) . . . . . . . 3⁄8"Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24"Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 3⁄8"Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 3⁄8"Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . 3⁄8"Discharge lip liner (AR plate) . . . . . . . . . . . . . . . . . . . 3⁄8"Bearing size: 6202 & 6203 . . . . . . . . . . . . . . . . . . . . . 140 mm

7202 & 7203 . . . . . . . . . . . . . . . . . . . . . 140 mm8202 & 8203 . . . . . . . . . . . . . . . . . . . . . 160 mm

Stroke (in.) RPM1⁄4 10003⁄16 1150

PATENT APPLIED FOR

135

In addition to the benefits described of the single shaftincline designs, JCI dual shaft incline screens will pro-vide increased bearing life as compared to a singleshaft arrangement, due to the load being distributedover additional bearing surface. In some cases, dualshaft screens will also provide the benefit of a moreaggressive screen action in applications where thefeed end of the screen becomes ìtop heavyî with ahigh volume of material.

JCI DUAL SHAFT INCLINED SCREENS

Standard stroke length (Amplitude) . . . . . . . . . . . . . . 3⁄8" strokeStandard operating speed. . . . . . . . . . . . . . . . . . . . . . 850 rpmOptional stroke and speed relationships . . . . . . . . . . .

Maximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 8"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . 4"Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . 18"Cloth support bar thickness (Rail thickness) . . . . . . . 3⁄8"Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24"Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 3⁄8"Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 3⁄8"Feed box liners (AR plate). . . . . . . . . . . . . . . . . . . . . . 3⁄8"Discharge lip liner (AR plate) . . . . . . . . . . . . . . . . . . . 3⁄8"Bearing size: 6202 & 6203 . . . . . . . . . . . . . . . . . . . . . 140 mm

7202 & 7203 . . . . . . . . . . . . . . . . . . . . . 140 mm8202 & 8203 . . . . . . . . . . . . . . . . . . . . . 160 mm

Stroke (in.) RPM3⁄16 12001⁄4 10501⁄2 750

PATENT APPLIED FOR

136

JCI COMBO screens combine the advantages of bothan inclined screen and a horizontal screen. The topdeck of the screen is equipped with incline panel sec-tions that begin with a 20-degree section, flatten to a10 degree section, and the remaining deck area is atzero degrees. The second deck begins at 15 degrees,flattens to 7.5 degrees, and the remaining deck is alsoat zero. The entire bottom deck is horizontal.

By installing sloped sections at the feed end, materialbed depth is reduced since gravity will increase thetravel speed of the material. This reduced bed depthminimizes spillover, and enables fine particles to “strat-ify” through the coarser particles and onto thescreening surface much faster, where it can then findmore opportunities to be passed through screen open-ings. This design also enables fines to be introduced tothe horizontal bottom deck faster, which increases thebottom deck screening capacity, or bottom deck factorused in the VSMA screen calculation.

JCI has also designed a punch plate section into thefeed plate itself, thereby increasing the total screeningarea by an additional 10%. This punch plate willremove a high percentage of fine particles before theyare even introduced to the actual screen deck, therebyincreasing production volumes.

The coarse “near” size and “over” size particles thatare not initially separated on the middle and top decksgradually slow down as the deck panels flatten out tothe horizontal section towards the discharge end of thescreen. This material’s reduced travel speed, com-bined with the optimum angle of trajectory in

JCI SCREENS

0°0°

0°

20°15°

7.5°10°

(Multi-Slope)

PATENT APPLIED FOR

relationship to the screen opening, provides a highscreening efficiency that oval motion horizontalscreens have built their reputation on.

The COMBO screen is also the only multi-slope designthat features a triple shaft design. This design providesan optimal oval screening motion that has proveneffective over decades of success in the company’straditional flat screen design. In addition to the featuresof the COMBO design, producers will also benefit byhaving the ability to adjust stroke length, stroke angle,and RPM speed to best suit the conditions of the appli-cation.

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 deck’s utilization,

thereby increasing volume and efficiency.

Although not as portable as the traditional horizontalscreens, the COMBO design will be an ideal screen fora variety of both scalping and product sizing applica-tions. The design is especially well suited for acceptinglarge volumetric feed ‘surges’, deposits containing ahigh percentage of fines that must be removed, instal-lations where screening capacity must be increasedwithin the same structural or mounting ‘footprint’, or inclosed circuit with crushers.

JCI COMBO screens are available in both a standardduty and finishing duty three deck configurations andare currently available in 6x20 and 8x20 sizes. JCICOMBO screens feature huck-bolt construction,incline deck panels that slope form 20 to zero degrees,adjustable stroke amplitudes, a hinged tailgate rearsection for maintenance access, and a perforated feedbox for additional screening area. COMBO screenscan be installed with either standard wire cloth or ure-thane/rubber deck panels.

137

138

Adjustable stroke length (Amplitude) . . . . . . . . . . . . . min 5⁄8" to max 3⁄4"(Stroke reduced by removing weight plugs.)

Adjustable stroke angle (Timing angle). . . . . . . . . . . . 30 to 60 degreesOperating speed range . . . . . . . . . . . . . . . . . . . . . . . . 675-875 rpmMaximum feed size . . . . . . . . . . . . . . . . . . . . . . . . . . . 10"Maximum top deck opening . . . . . . . . . . . . . . . . . . . . 514, 516 & 616 = 5"

620 & 720 = 4"Maximum drop of feed . . . . . . . . . . . . . . . . . . . . . . . . 18"Cloth support bar thickness (Rail thickness) . . . . . . . 3⁄8"Deck cross-member spacing . . . . . . . . . . . . . . . . . . . 24"Side Plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1⁄4"Reinforcing plate thickness. . . . . . . . . . . . . . . . . . . . . 5' & 6' = 1⁄4"

7' = 1⁄4"Discharge lip liner thickness (AR plate) . . . . . . . . . . . 1⁄4"Bearing size: 5142-24 & 5143-24 . . . . . . . . . . . . . . . . 120 mm

5162-26 & 5163-26. . . . . . . . . . . . . . . . 130 mm6162-32 & 6163-32. . . . . . . . . . . . . . . . 160 mm6202-32 & 6203-32. . . . . . . . . . . . . . . . 160 mm7202-38 & 7203-38. . . . . . . . . . . . . . . . 190 mm6202-32LP & 6203-32LP . . . . . . . . . . . 160 mm7202-38LP & 7203-38LP . . . . . . . . . . . 190 mm8202-38W & 8203-38W . . . . . . . . . . . . 190 mm

PATENT APPLIED FOR

JCI VIBRATING SCREEN – CAPACITYCALCULATIONS

139

Most manufacturers use a modified version of the VSMA(Vibrating Screen Manufactures Association) formula todetermine screen capacity. The twelve factors used in theformula below are based in large part on the VSMA chartsand 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 intons per hour.

B = Basic capacity per square foot in tons per hour (One ton = 2000 pounds)

S = Incline factorD = Deck factorV = Oversize factorH = Halfsize factorT = Slot factorK = Material condition factorY = Spray factorP = Shape factorO = Open area factorW = Weight factorF = Efficiency factor

There are other influences but which materially affect screenoperation. We have assembled this data and weighted it inaccordance with our experience. The additional factors weare suggesting are:

TYP = Type of stroke factor STR = Stroke length factorTIM = Timing angle factorRPM = Revolutions per minute factorNEA = Near size factorBED = Bed depth factor

The screen capacity formula with 6 new factors above nowbecomes: A = B * S * D * V * H * T * K * Y * P * O * W * F * TYP * STR

* TIM * RPM * NEA * BED

140

JCI EXPLANATION OF PARAMETERS

A = Actual capacity

B = Basic capacity

S = Incline factor

141

D = Deck factor

V = Over size factor

142

H = Half size factor

T = Slot factor

143

K = Material Condition factor

Y = Spray factor

144

P = Shape factor

O = Open Area factor

145

W = Weight factor

F = Efficiency factor

146

TYP = Type of Stroke Factor

147

STR = Stroke Length factor

148

TIM = Timing Angle Factor

149

RPM - Revolutions Per Mintue factor

150

NEA = Near Size factorChart 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

151

NEA = Near Size factor

152

BED = Bed Depth factorWhere 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 factorChart A - Conveying Velocity at 20° Incline

Incline Screen with Circular Stroke

153

SP = Conveying Speed factorChart B - Conveying Velocity at 15° Incline

Incline Screen with Circular Stroke

Chart C - Conveying Velocity at 10° InclineIncline Screen with Circular Stroke

154

SP = Conveying Speed factorChart A - Conveying Velocity at 60° Timing Angle Flat

Screens

155

SP = Conveying Speed factorChart B - Conveying Velocity at 55° Timing Angle Flat

Screens

Chart C - Conveying Velocity at 50° Timing Angle FlatScreens

156

SP = Conveying Speed factorChart D - Conveying Velocity at 45° Timing Angle Flat

Screens

Chart E - Conveying Velocity at 40° Timing Angle FlatScreens

157

SP = Conveying Speed factorChart F - Conveying Velocity at 35° Timing Angle Flat

Screens

Chart G - Conveying Velocity at 30° Timing Angle FlatScreens

158

WD = Width factor

NOTES:

159

160

KOLBERG SCREENS

INTRODUCTION

Vibrating screens are used to separate a mixture ofsizes of materials into categories of sizes. Sorting isdone by passing the mixed material along a surfacehaving uniform openings. Those particles smallenough to pass through the openings are called theundersize product and those particles too large to passthrough the openings are called the oversize productof those particular openings. The surface having theopenings is usually formed of woven wire and is calledscreen cloth. Coarse sorting is sometimes done on asteel plate surface having relatively large holes eithercut or punched in it. These wire cloths or punchedplate surfaces are held in superimposed frames calleddecks. Vibrating screens may have one, two, three orfour decks. The undersize of each deck falls to thatbelow it for additional sorting. The decks are held in abox-like structure. The box is mounted on a rotatingshaft made to vibrate. The vibration is induced by aneccentricity cut into the shaft or by counterweightsmounted on the ends of the shaft. Each revolution ofthe powered shaft lifts the box and its screening sur-faces and at the same time moves the entire assemblyforward. This causes the material on the decks to flowin a bouncing manner from the feed ends of the decksto the discharge ends. Suitable chutes and hoppersgather the several sizes of products produced.

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KOLBERG *FACTORS FOR CALCULATING SCREEN AREA**Formula: Screening Area = U

A x B x C x D x E x F x G x H x J*Basic Operating Conditions

Feed to screening deck contains 25% oversize and 40% halfsizeFeed is granular free-flowing materialMaterial weighs 100 lbs. per cu. ft.Operating slope of screen is: Inclined Screen 18° - 20° with flow rotation

Horizontal Screen 0°Objective Screening Efficiency—95%

FACTOR “A”Surface % STPHSquare Open PassingOpening Area A Sq. Ft.

4" 75% 7.69

31⁄2" 77% 7.03

3" 74% 6.17

23⁄4" 74% 5.85

21⁄2" 72% 5.52

2" 71% 4.90

13⁄4" 68% 4.51

11⁄2" 69% 4.20

11⁄4" 66% 3.89

1" 64% 3.567⁄8" 63% 3.383⁄4" 61% 3.085⁄8" 59% 2.821⁄2" 54% 2.473⁄8" 51% 2.081⁄4" 46% 1.603⁄16" 45% 1.271⁄8" 40% .953⁄32" 45% .761⁄16" 37% .581⁄32" 41% .39

FACTOR “B”(Percent of Oversize in Feed to Deck)

% Oversize 5 10 15 20 25 30 35Factor B 1.21 1.13 1.08 1.02 1.00 .96 .92

% Oversize 40 45 50 55 60 65 70Factor B .88 .84 .79 .75 .70 .66 .62

% Oversize 75 80 85 90 95Factor B .58 .53 .50 .46 .33

FACTOR “C”(Percent of Halfsize in Feed to Deck)

% Halfsize 0 5 10 15 20 25 30Factor C .40 .45 .50 .55 .60 .70 .80

% Halfsize 35 40 45 50 55 60 65Factor C .90 1.00 1.10 1.20 1.30 1.40 1.55

% Halfsize 70 75 80 85 90Factor C 1.70 1.85 2.00 2.20 2.40

FACTOR “E”(Wet Screening)

Opening 1⁄32" 1⁄16" 1⁄8" 3⁄16" 1⁄4" 3⁄8" 1⁄2" 3⁄4" 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 30Factor F 1.50 1.25 1.00 .90 .80 .75 .70 .60 .50 .30

FACTOR “G”(Screen Surface Open Area)

Factor “G” = % Open Area of Surface Being Used% Open Area Indicated in Capacity

FACTOR “D”(Deck Location)

Deck Top Second ThirdFactor D 1.00 .90 .80

FACTOR “H”(Shape of Surface

Opening)

Square . . . . . . . . . . 1.00Short Slot

(3 to 4 times Width) . . . . 1.15Long Slot

(More than 4 Times Width) . 1.20

FACTOR “J”(Efficiency)

95% . . . . . . . . . . . . 1.0090% . . . . . . . . . . . . 1.1585% . . . . . . . . . . . . 1.3580% . . . . . . . . . . . . 1.5075% . . . . . . . . . . . . 1.7070% . . . . . . . . . . . . 1.90

**Furnished by VSMA U = STPH Passing Specified Aperture

Kolberg Series 70: All series 70 screens are twobearing inclined screens and include base frame withC spring suspension and electric motor drives. Thesescreens are a medium-light duty screen and typicallyare used to size material down to #4 mesh and up to 3"maximum. They are available in a range of sizes from2' x 4' to 5' x 12'.

Series 71 is a “Conventional Screen” and is availablein single, double or triple deck configurations. Eachdeck has side tensioned cloth. They operate at anincline of approximately 15°.

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SINGLE DECKModel Size Speed Motor71-1D244 24" x 4' 15-1700 2 HP71-1D366 36" x 6' 14-1600 3 HP71-1D368 36" x 8' 14-1600 3 HP71-1D486 48" x 6' 14-1600 3 HP71-1D488 48" x 8' 13-1500 5 HP

DOUBLE DECKModel Size Speed Motor71-2D366 36" x 6' 14-1600 3 HP71-2D486 48" x 6' 13-1500 5 HP71-2D488 48" x 8' 13-1500 7-1/2 HP71-2D4810 48" x 10' 11-1300 10 HP

TRIPLE DECKModel Size Speed Motor71-3D366 36" x 6' 13-1500 5 HP71-3D488 48" x 8' 11-1300 10 HP

Series 77 is a “Vibrating Grizzly” and is available insingle or double deck configurations. Grizzly Bars areavailable in fixed or adjustable configurations. Singledeck configurations include grizzly bars only. Doubledeck configurations include grizzly bars on the topdeck and side tensioned screen cloth on the bottomdeck. Coil impact springs are mounted inside of the Csprings. They operate at an incline angle of approxi-mately 15°.

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SINGLE DECKModel Size Speed Motor77-1DG-(F or A) 366 36" x 6' 13-1500 7-1/2 HP77-1DG-(F or A) 488 48" x 8' 11-1300 10 HP

DOUBLE DECKModel Size Speed Motor77-2DG-(F or A) 488 48" x 8' 11-1300 15 HP77-2DG-(F or A) 4810 48" x 10' 11-1300 15 HP

Series 72 is a “Desander” and is available in a doubledeck configuration. The top deck cloth is side ten-sioned and the bottom deck cloth is end tensioned –harp wire type. They operate at an incline of 15° to50°.

DOUBLE DECKModel Size Speed Motor72-2D488 48" x 8' 11-1300 7-1/2 HP72-2D4810 48" x 10' 11-1300 10 HP72-2D4812 48" x 12' 11-1300 10 HP72-2D6010 60" x 10' 11-1300 10 HP72-2D6012 60" x 12' 11-1300 10 HP

Note: F = Fixed grizzly barsA = Adjustable grizzly bars

Model 241: This plant is designed for the lower TPHapplications. It includes an 8 cu.yd. hopper, 30" beltfeeder, 24" conveyor and 4'x6' two deck screen asstandard.

Model 271: This plant is the most versatile size andcan generally be used in most applications. It includesa 9 cu.yd. hopper, 36" belt feeder, 30" conveyor and4'x8" two deck screen as standard. Screen angle canbe adjusted “on-the-fly”.

Model 291: This plant is designed for the larger TPHapplication. It includes a 12 cu.yd. hopper, 42" beltfeeder, 42" conveyor and 5'x12' two deck screen.Screen angle can be adjusted “on-the-fly”.

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Kolberg Portable Screening Plants: There are fourdifferent models of Kolberg portable screening plants -Models 241, 271, 291 and 391. These plants are allhydraulic with Seal-Lok®, O-ring fittings and includeself-contained diesel engine power units. The hopperdesign features a vertical front wall and 70° rear andside walls for improved material flow. The screen is atwo bearing design with double row spherical rollerbearings for long service life. Screen adjustments canbe made for improved screen efficiency. These adjust-ments include: adjustable screen speed, adjustablethrow, adjustable screen angle and reversal of screenrotation.

These plants are medium duty plants with scalpinggrizzly set at 6" spacing. Applications for these plantsinclude: sand and gravel, sand washing, recycle, top-soil, compost, ash, peat, sludge, aglime, clay, coal andaggregates.

(Model 271shown)

Model 391: This plant is designed for optimum portabilitywith three on-board discharge conveyors that quickly andeasily 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 con-veyor.

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Model 241 Model 271 Model 291 Model 391

Sand & Gravel TPH Up to 250 Up to 350 Up to 650 Up to 600

Soil TPH Up to 150 Up to 250 Up to 550 Up to 400

Hopper Capacity 8 cu.yd. 9 cu.yd. 12 cu.yd. 12 cu.yd.

Belt Feeder 30" x 11'-6" 36" x 11'-6" 42" x 12' 42" x 14'

Feed Conveyor 24" x 40' 30" x 40' 42" x 43' 36" x 38'

Std. Screen Size 4' x 6', 2 deck 4' x 8', 2 deck 5' x 12', 2 deck 5' x 12', 2 deck

Optional Screen 4' x 8', 2 deck 4' x 10', 2 deck n/a n/aSize 4' x 8', 3 deck

On-BoardConveyors n/a n/a n/a three (3)

Power 62 HP 80 HP 165 HP 114 HP

KOLBERG PORTABLE SCREENING PLANTS

Model 291

Model 391

Model 391-T

KOLBERG DIRECT SCREEN (KDS)

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There are two different models of Kolberg direct feedscreens. Models 708 KDS and 710 KDS. These plantsare all hydraulic with Parker Seal-Lok®, O-ring fittingsand include self-contained diesel power units.

708 KDS 710 KDSScreen Size 8'-0" x 6'-81⁄2" 10'-0" x 6'-81⁄2"

Opening for theLoader Bucket 10'-0" 12'-0"Loader Bucket

Cu. Yd. 1 to 3 3 to 5Landing Gear Hydraulic Hydraulic

Optional Field 48" x 35'

Replaceable FinesConveyor N/A Conveyor

NOTES:

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CONVEYORS—INTRODUCTIONBelt conveyors are designed to carry material via theshortest distance between the loading and unloadingpoints. When required, belt conveyors can operatecontinuously, without loss of time and are capable ofhandling tonnages of bulk materials that would bemore costly and often impractical to transport by othermeans. This often avoids confusion, delays, andsafety hazards of rail and motor traffic in plants andother congested areas.

Choosing the right conveyor starts with looking at thefive basic considerations: material characteristics,conveyor length and discharge height, TPH feed, con-veyor width and HP requirements.

1. Material Characteristicsa. Variables include: Particle Shape, Particle Size,Moisture, Angle of Repose, Lump Size & % Fines andWeight. Characteristics normally used as a rule ofthumb include: 100 lbs. per cubic foot density, 37degree angle of repose and less than 25% of a max. 3"lump.

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° Angle ° AngleMaterial Incline % Grade Material Incline % GradeAlumina . . . . . . . . . . . . . . . 10-12 17.6-21.2 Gypsum, 1/2" Screening . . . 21 38.3Ashes, Coal, Dry, 1/2" Gypsum, 1-1/2" to 3"and Under . . . . . . . . . . . . 20-25 36.4-46.6 Lumps . . . . . . . . . . . . . . . . 15 26.8

Ashes, Coal, Wet, 1/2" Earth—Loose and Dry. . . . . 20 36.4and Under . . . . . . . . . . . . 23-27 42.4-50.4 Lime, Ground, 1/8"

Ashes, Fly. . . . . . . . . . . . . . 20-22 36.4-40.4 and Under . . . . . . . . . . . . . 23 42.4Bauxite, Ground, Dry . . . . . 20 36.4 Lime, Pebble . . . . . . . . . . . . 17 30.6Bauxite, Mine Run . . . . . . . 17 30.6 Limestone, Crushed . . . . . . 18 32.5Bauxite, Crushed 3" Limestone, Dust . . . . . . . . . 20 36.4and Under . . . . . . . . . . . . 20 36.4 Oil Shale . . . . . . . . . . . . . . . 18 32.5

Borax, Fine . . . . . . . . . . . . . 20-25 36.4-46.6 Ores—Hard—PrimaryCement, Portland . . . . . . . . 23 42.4 Crushed. . . . . . . . . . . . . . . 17 30.6Charcoal . . . . . . . . . . . . . . . 20-25 36.4-46.6 Ores—Hard—SmallCinders, Blast Furnace . . . . 18-20 32.5-36.4 Crushed Sizes . . . . . . . . . . 20 36.4Cinders, Coal . . . . . . . . . . . 20 36.4 Ores—Soft—NoCoal Crushing Required . . . . . . 20 36.4Bituminous, Run of Mine . 18 32.4 Phosphate Triple Super,. . . . Bituminous, Fines Only . . 20 36.4 Ground Fertilizer . . . . . . . . 30 57.7Bituminous, Lump Only . . 16 28.6 Phosphate Rock,Anthracite, Run of Mine . . 16 28.6 Broken, Dry . . . . . . . . . . . . 12-15 21.2-26.8Anthracite, Fines . . . . . . . 20 36.4 Phosphate Rock, Pulverized 25 46.6Anthracite, Lump Only . . . 16 28.6 Rock, Primary Crushed . . . . 17 30.6Anthracite, Briquettes. . . . 12 21.3 Rock, Small Crushed Sizes . 20 36.4

Coke—Run of Oven . . . . . . 18 32.4 Sand—Damp. . . . . . . . . . . . 20 36.4Coke, Breeze . . . . . . . . . . . 20 36.4 Sand—Dry . . . . . . . . . . . . . 15 26.8Concrete—Normal . . . . . . . 15 26.8 Salt . . . . . . . . . . . . . . . . . . . 20 36.4Concrete—Wet Soda Ash (Trona) . . . . . . . . 17 30.6(6" Slump) . . . . . . . . . . . . 12 21.3 Slate, Dust. . . . . . . . . . . . . . 20 36.4

Chips—Wood . . . . . . . . . . 27 50.9 Slate, Crushed, 1/2"Cullet . . . . . . . . . . . . . . . . . 20 36.4 and Under . . . . . . . . . . . . . 15 26.8Dolomite, Lumpy . . . . . . . . 22 40.4 Sulphate, Powder . . . . . . . . 21 38.3Grains—Whole . . . . . . . . . 15 26.8 Sulphate, Crushed—1/2" . . . Gravel—Washed . . . . . . . . 15 26.8 and Under . . . . . . . . . . . . . 20 36.4Gravel and Sand. . . . . . . . . 20 36.4 Sulphate, 3" and Under . . . . 18 32.5Gravel and Sand Taconite—Pellets . . . . . . . . 13-15 23.1-26.8Saturated . . . . . . . . . . . . . 12 21.3 Tar Sands . . . . . . . . . . . . . . 18 32.5

Gypsum, Dust Aerated . . . . 23 42.4

NOTE: *When mass slips due to water lubrication rib type belts permit three to five degrees increase.

RECOMMENDED MAXIMUM ALLOWABLE INCLINEFOR BULK MATERIALS

b. Material characteristics can affect other elements ofconveyor selection.

• Heavier material or large lumps may require moreHP, heavier belt, closer idler spacing and impactidlers at feed points.

• Abrasiveness may require wear liners or specialrubber compositions.

• Moisture may require steeper hopper sides, widerbelts, anti-buildup return idlers and special beltwipers.

• Dust content may require special discharge hoodsand chutes, slower belt speeds and hood covers.

• Sharp material may require impact idlers, wear lin-ers, special belt and plate feeder.

• Lightweight materials may require wider belts andless horsepower.

c. Conveyor Belt

Conveyor belt consists of three elements: top cover,carcass and bottom cover.

The belt carcass carries the tension forces necessaryin starting and moving the loaded belt, absorbs theimpact energy of material loading, and provides thenecessary stability for proper alignment and load sup-port over idlers under all operating conditions.

Because the primary function of the cover is to protectthe carcass, it must resist the wearing effects of abra-sion and gouging, which vary according to the type ofmaterial conveyed. The top cover will generally bethicker than the bottom cover because the concentra-tion of wear is usually on the top, or carrying side.

The belt is rated in terms of “maximum recommendedoperating tension” pounds per inch of width (PIW).The PIW of the fabric used in the belt is multiplied bythe number of plies in the construction of the belt todetermine the total PIW rating of the belt.

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d. Idlers

Idler selection is based on the type of service, operat-ing condition, load carried and belt speed.

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RollFormer Diameter

Classification Series No. (Inches) Description

A4 I 4 Light DutyA5 I 5 Light DutyB4 II 4 Light DutyB5 II 5 Light DutyC4 III 4 Medium DutyC5 III 5 Medium DutyC6 IV 6 Medium DutyD5 NA 5 Medium DutyD6 NA 6 Medium DutyD7 VI 7 Heavy DutyE6 V 6 Heavy Duty

CEMA IDLER CLASSIFICATION

2. Length

Length is determined one of three ways:

a. Lift Height Required: When lift height is the deter-mining factor, as a rule of thumb an 18 degree inclineis used, where 3 x height needed appriximates theconveyor length required. Particle size, moisture andother factors affect the maximum incline angle. If thematerial tends to have a conveyable angle that is lessthan 18 degrees, a longer conveyor needs to beselected to achieve the desired lift height.

b. Distance to be conveyed

c. Stockpile Capacity Desired

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CONVEYOR ELEVATION CHART

HORIZONTAL DISTANCE IN FEET

CONVEYOR LENGTH IN FEET

40'

40' 50' 60'80'

100'120'

150'

21°

18°

15°

12°

9°

50' 60' 80' 100' 120' 150'

60'

50'

40'

30'

5'10'

20'

EL

EVA

TIO

N IN

FE

ET

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CONVEYOR ELEVATIONConveyor Length Conveyor Angle Height (ft.)

40 12 10.340 15 12.440 18 14.440 21 16.360 12 14.560 15 17.560 18 20.560 21 23.580 12 18.680 15 22.780 18 26.780 21 30.7100 12 22.8100 15 27.9100 18 32.9100 21 37.8120 12 26.9120 15 33.1120 18 39.1120 21 45.0150 12 33.2150 15 40.8150 18 48.4150 21 55.8

LL

2'

H

Head Pulley

H=Sinθ(L)+2'

C

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"D" APPROX

"H"

37.5°37.5°DEADSTORAGE

LIVE STORAGE

Live Capacity is the part of pile that can be removed with one feed chute atthe center of pile. Approximately 1⁄4 of gross capacity of pile.

GROSS VOLUME = 1⁄3 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°

CONICAL STOCKPILE CAPACITYVolume Volume

Tons Tons(100 lbs. (100 lbs.

H D Cu. Yds. /cu. ft.) H D Cu. Yds. /cu. ft.)

6 16 14 19 26 68 1158 15638 21 34 46 28 73 1446 1952

10 26 66 89 30 78 1779 240112 31 114 154 35 91 2824 381314 36 181 244 40 104 4216 569116 42 270 364 45 117 6003 810418 47 384 519 50 130 8234 1111620 52 527 711 55 143 10960 1479522 57 701 947 60 156 14228 1920824 63 911 1229

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APPROXIMATE VOLUME OFCIRCULAR STOCKPILE

V3 = V1 + V2θ

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 = 1187

H = Height of Stockpile - in feetR = Radius of Arc (C Pile to C Pivot) - in feet

NOTE: V2 based on 37.5° angle of reposeθ = Angle of Arc - in degrees

H2R

L L

V1

2

R

VOLUME OF STOCKPILESEGMENT FOR 1° ARC V2

V1

2

θ

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V2 = Volume of Stockpile Segment for 1 degree Arc (cu. yds.)

Radius(in feet) 10 15 20 25 30 35 40 45 50 55

25 2.130 2.535 2.9 6.640 3.4 7.645 3.8 8.550 4.2 9.5 16.855 4.6 10.4 18.560 5.1 11.4 20.2 31.665 5.5 12.3 21.9 34.270 5.9 13.3 23.6 36.975 6.3 14.2 25.3 39.5 56.980 6.7 15.2 27.0 42.1 60.785 7.2 16.1 28.6 44.8 64.4 87.790 7.6 17.1 30.3 47.4 68.2 92.995 8.0 18.0 32.0 50.0 72.0 98.0100 8.4 19.0 33.7 52.7 75.8 103.2 134.8105 8.8 19.9 35.4 55.3 79.6 108.4 141.5110 9.3 20.9 37.1 57.9 83.4 113.5 148.3 187.7115 9.7 21.8 38.8 60.6 87.2 118.7 155.0 196.2120 10.1 22.7 40.4 63.2 91.0 123.8 161.8 204.7 252.7125 10.5 23.7 42.1 65.8 94.8 129.0 168.5 213.2 263.3130 11.0 24.6 43.8 68.4 98.6 134.2 175.2 221.8 273.8135 11.4 25.6 45.5 71.1 102.4 139.3 182.0 230.3 284.3 344.0140 11.8 26.5 47.2 73.7 106.1 144.5 188.7 238.8 294.9 356.8145 12.2 27.5 48.9 76.3 109.9 149.6 195.5 247.4 305.4 369.5150 12.6 28.4 50.5 79.0 113.7 154.8 202.2 255.9 315.9 382.3

3. TPH Feed

See belt carrying capacity chart. As a rule of thumb, at350 fpm, 35 degree troughing idlers and 100 lbs/cu. ft.material, a 24" belt carries 300 TPH, a 30" belt carries600 TPH and a 36" belt carries 900 TPH.

Stockpile Height (H) in Feet

L H R V1 V1 V2 V2 V3 V390° 90°

stockpile stockpileFeet Feet Feed Cu. Yds. Tons Cu. Yds. Tons Cu. Yds. Tons60 20.5 57 567 766 20.2 27.3 2,385 3,22380 26.7 76 1,254 1,693 45.6 61.6 5,358 7,237100 32.9 95 2,346 3,167 86.6 116.9 10,140 13,688120 39.1 114 3,938 5,316 146.8 198.2 17,150 23,154150 48.4 142.5 7,469 10,083 281.2 379.6 32,777 44,247

Examples:

176 CONVEYOR BELT CARRYING CAPACITY AT VARIOUS SPEEDS

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.

Belt Capacity in Tons Per Hour*Width Belt Speeds F.P.M.Inches 100 150 200 250 300 350 400 450 500 550 600

18 69 103 138 172 207 241 276 310 345 379 414

24 132 198 264 330 396 462 528 594 660 726 792

30 215 322 430 537 645 752 860 967 1075 1182 1290

36 318 477 636 795 954 1113 1272 1431 1590 1749 1908

42 441 661 882 1102 1323 1543 1764 1984 2205 2425 2646

48 585 877 1170 1462 1755 2047 2340 2632 2925 3217 3510

54 748 1122 1496 1870 2244 2618 2992 3366 3740 4114 4488

60 932 1398 1864 2330 2796 3262 3728 4194 4660 5126 5592

72 1360 2040 2720 3400 4080 4760 5440 6120 6800 7480 8160

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4. Conveyor Width

There are a number of factors that affect width. Theseinclude TPH feed, future considerations, lump size andthe % of fines, cross section of how the material settleson the belt and material weight.

a. Normally portable conveyors are set-up to run at350 feet per minute, as this is accepted as the bestspeed for the greatest number of types of material andoptimum component life. When it is desirable to run ata different speed, this will usually be a factory decisionbased on the material and the capabilities requestedby the customer. These variations are generallyapplicable on engineered systems.

RECOMMENDED MAXIMUM BELT SPEEDSBelt Speeds Belt Width

Material being conveyed (fpm) (inches)

Grain or other free-flowing, nonabrasive 500 18material 700 24-30

800 36-421000 48-96

Coal, damp clay, soft ores, overburden and 400 18earth, fine-crushed stone 600 24-36

800 42-601000 72-96

Heavy, hard, sharp-edged ore, 350 18coarse-crushed stone 500 24-36

600 Over 36

Foundry sand, prepared or damp; shakeoutsand with small cores, with or without small 350 Any widthcastings (not hot enought to harm belting)

Prepared foundry sand and similar damp (ordry abrasive) materials discharged from belt 200 Any widthby rubber-edged plows

Nonabrasive Materials discharged from belt 200 Any widthby means of plows except for

wood pulp,where 300 to

400 ispreferable

Feeder belts, flat or troughed, for feedingfine, nonabrasive, or midly abrasive materials 50 to 100 Any widthfrom hoppers and bins

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b. Lump size and the % of fines can have a majoraffect on width selection. As a rule of thumb, the fol-lowing should be utilized.

Width All Lumps 90% Fines18" 2" Max. 3"24" 21⁄2" 4"30" 3" 5"36" 31⁄2" 6"42" 4" 7"

Belts must be wide enough so any combination oflumps and fine material do not load the lumps tooclose to the edge of the belt.

c. The cross section of how the material settles on amoving belt can have a major affect on expected ton-nage for a given width conveyor.

FACTORS AFFECTING THE CROSS SECTION ARE:

• The angle of repose of a material is the angle thatthe surface of a normal, freely formed pile, makes tothe horizontal.

• The angle of surcharge of a material is the angleto the horizontal that the surface of the materialassumes while the material is at rest on a movingconveyor belt. This angle usually is 5° to 15° lessthan the angle of repose, though in some materialsit may be as much as 20° less.

• The flowability of a material, as measured by itsangle of repose and angle of surcharge, determinesthe cross-section of the material load that safelycan be carried on a belt. It also is an index of thesafe angle of incline of the belt conveyor. Theflowability is determined by such material charac-teristics as: size and shape of the fine particles andlumps, roughness or smoothness of the surface ofthe material particles, proportion of fines and lumpspresent, and moisture content of material.

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FLOWABILITY—ANGLE OF SURCHARGE—ANGLE OF REPOSE

Very freeflowing Free flowing Average Flowing Sluggish

5° Angle of 10° Angle of 20° Angle of 25° Angle of 30° Angle ofsurcharge surcharge surcharge surcharge surcharge

0°-19° Angle 20°-29° Angle 30°-34° Angle 35°-39° Angle 40°-up Angleof repose of repose of repose of repose of repose

MATERIAL CHARACTERISTICSUniform size, Rounded, dry Irregular, granu- Typical common Irregular,very small polished particles, lar or lumpy materials such as stringy, fibrous,rounded particle, of medium weight, materials of bituminous coal, interlocking mate-either very wet or such as whole medium weight, stone, most ores, ial, such as woodvery dry, such as grain or beans. such as anthra- etc. chips, bagasse,dry silica sand, cite coal, cotton- tempered foundrycement, wet con- seed meal, clay, sand, etc.crete, etc. etc.

d. The material weight affects the volume, whichaffects the width. Most aggregate weighs between 90-110 lbs. per cubic foot. When the weight variessignificantly, it can have a dramatic effect on expectedbelt width needed to achieve a given tonnage.

5. HP Requirements

The power required to operate a belt conveyor dependson the maximum tonnage handled, the length of theconveyor, the width of the conveyor and the verticaldistance that the material is lifted. Factors X + Y + Z(from tables below) = Total HP Required at Head-shaft. The figures shown are based on averageconditions with a uniform feed and at a normal operat-ing speed. Additional factors such as pulley friction,skirtboard friction, material acceleration and auxiliarydevice frictions (mechanical feeder, tripper, etc.) mayrequire an increase in horsepower.

Drive efficiency is taken into consideration to deter-mine the motor horsepower required. This can be anadditional 10-15% above the headshaft HP. The abil-ity to start a loaded conveyor will also require anadditional HP consideration.

180

Center-Center of PulleysTPH 25' 50' 75' 100' 150' 200' 250' 300' 350' 400'100 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.3 1.4 1.5150 0.8 0.9 1.0 1.1 1.3 1.5 1.7 1.9 2.1 2.3200 1.0 1.2 1.3 1.5 1.7 2.0 2.2 2.5 2.8 3.0250 1.3 1.5 1.6 1.9 2.1 2.5 2.8 3.1 3.5 3.8300 1.5 1.8 2.0 2.3 2.6 3.0 3.3 3.8 4.2 4.5350 1.8 2.1 2.3 2.6 3.0 3.5 3.9 4.4 4.9 5.3400 2.0 2.4 2.6 3.0 3.4 4.0 4.4 5.0 5.6 6.0500 2.5 3.0 3.3 3.8 4.3 5.0 5.5 6.3 7.0 7.5600 3.0 3.6 3.9 4.5 5.1 6.0 6.6 7.5 8.4 9.0700 3.5 4.2 4.6 5.3 6.0 7.0 7.7 8.8 9.8 10.5800 4.0 4.8 5.2 6.0 6.8 8.0 8.8 10.0 11.2 12.0900 4.5 5.4 5.9 6.8 7.7 9.0 9.9 11.3 12.6 13.51000 5.0 6.0 6.5 7.5 8.5 10.0 11.0 13.0 14.0 15.0

FACTOR Z - HORSEPOWER REQUIRED TO LIFT LOAD ON BELT CONVEYORLift

TPH 10' 20' 30' 40' 50' 60' 70' 80' 90' 100'100 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0150 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12.0 13.5 15.0200 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0250 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0300 3.0 6.0 9.0 12.0 15.0 18.0 21.0 24.0 27.0 30.0350 3.5 7.0 10.5 14.0 17.5 21.0 24.5 28.0 31.5 35.0400 4.0 8.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0500 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0600 6.0 12.0 18.0 24.0 30.0 36.0 42.0 48.0 54.0 60.0700 7.0 14.0 21.0 28.0 35.0 42.0 49.0 56.0 63.0 70.0800 8.0 16.0 24.0 32.0 40.0 48.0 56.0 64.0 72.0 80.0900 9.0 18.0 27.0 36.0 45.0 54.0 63.0 72.0 81.0 90.01000 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0

FACTOR X - HORSEPOWER REQUIRED TO OPERATE EMPTY CONVEYOR AT 350 FPMCon- Center-Center of PulleysveyorWidth 25' 50' 75' 100' 150' 200' 250' 300' 350' 400'

18" 0.7 0.8 0.9 1.1 1.2 1.3 1.4 1.7 1.8 2.024" 0.9 1.1 1.2 1.4 1.6 1.8 2.0 2.1 2.3 2.530" 1.4 1.6 1.8 1.9 2.2 2.5 2.8 3.0 3.2 3.536" 1.8 2.0 2.1 2.6 2.9 3.1 3.4 3.8 4.2 4.442" 2.1 2.5 2.7 3.0 3.5 3.7 4.2 4.6 5.3 6.048" 2.7 2.8 3.2 3.4 3.7 4.2 5.3 5.6 6.2 6.7

FACTOR Y - ADDITIONAL HP REQUIRED TO OPERATE LOADED CONVEYOR ON THE LEVEL

181

HOW TO DETERMINE CONVEYOR BELT SPEEDFive (5) factors are required to determine conveyorbelt speed.

A = Motor RPMB = Motor Sheave Dia. (inches)C = Reducer Sheave Dia. (inches)D = Reducer RatioE = Dia. of Pulley (inches)

A x B ÷ C = Reducer Input Speed (RPM)

Reducer Input Speed (RPM) ÷ D = Drive PulleyRPM

Drive Pulley RPM x 0.2618 x E = Conveyor BeltSpeed (FPM)

Example: Determine Conveyor Belt Speed of a 30" x60' conveyor with a 15 HP, 1750 RPM electric motordrive, 16" head pulley, 6.2" diameter motor sheave,9.4" diameter reducer sheave and a 15:1 reducer.

A = 1750 RPMB = 6.2C = 9.4D = 15E = 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 ConveyorBelt 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.

182

Kolberg Pioneer Inc. manufactures a variety of portableand stationary conveyors designed to meet the cus-tomer’s requirements. As a rule of thumb, Kolbergconveyors are designed with a Class I Drive, 220 PIW2-ply belt, 5" CEMA B idlers and a belt speed of 350fpm. At 350 fpm belt speed, basic capacities are: 24"belt width up to 300 TPH; 30" belt width up to 600TPH; 36" belt width up to 900 TPH.

CONVEYOR OPTIONS include: belt cleaners; verticalgravity take-up; horizontal gravity take-up; snub pulley;return belt covers; full hood top belt covers; impactidlers; self-training troughing idlers; self-training returnidlers; 220 PIW 2-ply belting with 3⁄16" top covers and1⁄16" bottom covers; 330 PIW 3-ply belting with 3⁄16" topcovers and 1⁄16" bottom covers; CEMA C idlers; walk-way 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. Usedprimarily as radial stacking conveyors with Kolbergportable screening plants. Come equipped withhydraulic drives to be powered from an auxiliarysource.

MODEL SIZE MOTOR2-2440 24" x 40' hyd. 2-2450 24" x 50' hyd. 2-3050 30" x 50' hyd.

Series 11: Portable, standard duty, lattice frame utilityconveyors. Used as transfer conveyors or radialstacking conveyors.

MODEL SIZE MOTOR11-2440 24" x 40' 7.5 HP 11-2450 24" x 50' 10 HP 11-2460 24" x 60' 10 HP 11-2470 24" x 70' 10 HP

11-3040 30" x 40' 10 HP 11-3050 30" x 50' 15 HP 11-3060 30" x 60' 15 HP 11-3070 30" x 70' 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

184

Series 12: Portable, standard duty, lattice frame feedconveyors and surge bins. Series 11: 30" or 36" wideconveyor incorporating various hopper/feeder combi-nations.

• Gravity feed hoppers are used primarily in “freeflowing” materials and are installed directly over theconveyor tail end and are used with top loadingequipment.

• Feeder hoppers generally provide a more accuratemetering of material than does a gravity hopper.

• Belt feeder/hopper – belt feeders are commonlyused and recommended for handling sand andgravel and sticky materials, such as clay or topsoilthat tend to build-up in other types of feeders. Ahopper is mounted above the feeder for use withtop loading equipment.

• Reciprocating plate feeder/hoppers – reciprocat-ing plate feeders are used in a free-flowing sandand gravel to minimize impact directly to the con-veyor belt. A hopper is mounted above the feederfor use with top loading equipment.

• Gravity feed dozer trap is used primarily in “freeflowing” materials when push loading material witha dozer. Material feeds directly to conveyor belt.

• Belt feeder/dozer trap – includes belt feeder asdescribed above with feed coming from a dozerpushing material into the dozer trap.

• Plate feeder/dozer trap – includes plate feeder asdescribed above with feeder coming from a dozerpushing material into the dozer trap.

185

Series 13: Portable, standard duty, lattice frame con-veyors. Most often used as radial stacking conveyors.Top folding option for road portability.

MODEL SIZE MOTOR13-2480 24" x 80' 10 HP 13-24100 24" x 100' 15 HP 13-24125 24" x 125' 15 HP

13-3080 30" x 80' 20 HP 13-30100 30" x 100' 25 HP 13-30125 30" x 125' 25 HP

13-3680 36" x 80' 25 HP 13-36100 36" x 100' 30 HP 13-36125 36" x 125' 40 HP

Other widths available upon request.

186

Series 31: Portable, heavy duty, lattice frame radialstacking conveyors. Side-folding for road portability.Cam-arm style undercarriage for constant radial travelradius.

MODEL SIZE MOTOR31-2480 24" x 80' 10 HP 31-24100 24" x 100' 15 HP31-24125 24" x 125' 15 HP

31-3080 30" x 80' 20 HP31-30100 30" x 100' 25 HP31-30125 30" x 125' 25 HP

31-3680 36" x 80' 25 HP31-36100 36" x 100' 30 HP31-36125 36" x 125' 40 HP

187

Series 33: Portable, heavy duty, telescoping radialstacking conveyors. Because of the stacker’s ability tomove in three directions: raise/lower, radial andextend/retract, it is effective in reducing segregationand degradation of material stockpiles.

Unique axle arrangement allows for quick set-up ofstacker. Road travel suspension of (8) eight 11:00-22.5tires on tandem walking beam axle. Gull wing radialstockpiling axle assembly of (4) four 15:00-22.5 tires.Gull wing is hydraulically actuated to lift travel tires offthe ground for radial stockpiling. (2) Two horsepowerplanetary power travel drives are included.

Automated stockpiling with PLC controls is availableon all models.

CONVEYORLENGTH MOTOR

RETRACTED/ MAIN CONV./MODEL SIZE EXTENDED EXT. CONV.

33-30110 30" x 110' 60'/110' 15 HP/15 HP33-30130 30" x 130' 70'/130' 20 HP/20 HP33-30150 30" x 150' 80'/150' 20 HP/20 HP33-36130 36" x 130' 70'/130' 30 HP/25 HP33-36150 36" x 150' 80'/150' 30 HP/30 HP

188

AREA #3 AREA #2 AREA #1

70'/130' TELESCOPING STACKER

CONVENTIONAL STOCKPILE AREA #1 100%NON-SEGREGATED STOCKPILE AREA #2 63%

FULL CAPACITY AREA #3 137%

189

Series 35: In pit, heavy duty, fixed height radial stackers.


Other belt widths and lengths available.


36-30100 30" x 100' 30 HP 36-30125 30" x 125' 30 HP 36-30150 30" x 150' 40 HP

36-36100 36" x 100' 50 HP 36-36125 36" x 125' 50 HP 36-36150 36" x 150' 60 HP

Other belt widths and lengths available.

Series 36: In pit, heavy duty, adjustable height, masttype cable suspended radial stackers.

190

SPECIALTY CONVEYORS INCLUDE:• Series 40T: Transflite conveyors (also known as

grasshopper conveyors) which are semi-mobile,overland transfer conveyors. Standard sizes are24", 30", 36" belt widths x 60', 80', 100' lengths.May have a single axle near the discharge end orone skid type support. Transflite conveyors areeasily moved around in the pit. Other sizes areavailable.

• Series 47S: Stackable conveyors. Made with a24" overall height frame of channel iron and anglewith the components recessed in the frame. Up to8 conveyors can be stacked on one trailer for multi-ple unit transport. Standard sizes are 24", 30" and36" belt widths x 50' or 60' lengths. Often used astransfer conveyors in portable crushing and screen-ing spreads.

• Series 47SP: Portable 36" x 50' or 60' stackableconveyor with special hinged frame section andhold down wheels. Often used as under crusherdischarge conveyor or under the discharge chutesof portable screening plants where clearance isminimal. Also known as “Dogleg” conveyors.

Series 40: Interplant feed and transfer conveyors, sta-tionary conveyors and specialty conveyors. Includesoverland systems thousands of feet long to bring mate-rial from the mining area to the processing plant.

Standard belt widths are 24", 30" and 36". Other beltwidths are available. Lengths are built to specification.Standard frames are 8" channel, 24", 30", 36" and 42"deep angle iron lattice trusses.

NOTES:

191

192

PUGMILLSINTRODUCTION:

Pugmills are used to blend together one or more dryingredients and/or liquid ingredients into a homoge-neous mixture. They were originally developed to mixan aggregate with a liquid bituminous material for acold mix asphalt. Today they are used for a number ofapplications including: cold mix asphalt; cementtreated based; soil remediation; etc.

The Kolberg design is a continuous mix pugmill. Itincludes two shafts with paddles on each shaft. Theshafts are driven by one drive with a set of timing gearsbetween the shafts. The paddles, arranged in a spiralpattern overlap, enhance the quality of the mix. Max.feed size to the pugmill is 2". The max. clearancebetween the paddle and the wall is 2". This can beadjusted to a min. of 3/4". The paddles can also berotated to increase wear life, as well as increase reten-tion time in the chamber. The pugmill also comesstandard with replaceable wear liners, drop-out bottomfor ease of clean-out and a dam gate.

The pugmill is available in three sizes:

Model Size Motor Number of Paddles50-486 48" x 6' 60 HP 4050-488 48" x 8' 75 HP 4850-4810 48" x 10' 100 HP 64

The most convenient way to utilize a pugmill is on aportable chassis. Kolberg offers three (3) differentconfigurations of portable plants.

Model 52This plant features a 9 cu.yd. hopper with 36" beltfeeder, 30" incline feed conveyor and 4' x 6' pugmilllocated at the end of the plant. It is all electric with anoptional on-board genset. It comes on a portablechassis with standard travel features – fifth wheelhitch, brakes, lights and mudflaps. A second 6 cu.yd.hopper is available as an option.

Model 52SThis plant is similar to the Model 52, but larger withmore pugmill HP and higher capacity. It includes a 13cu.yd. primary hopper with 36" belt feeder, 11 cu.yd.secondary hopper with 36" belt feeder, 36" wide inclinefeed conveyor and a 4' x 8' pugmill located at the endof the plant. This plant is all electric and comes on aportable chassis. Genset optional.

Model 53This plant is highly portable with an 8'6" wide travelwidth. It includes a 5 cu.yd. gravity hopper, 30" wideincline feed conveyor, 4' x 6' pugmill and a 30" x 25'discharge conveyor. This plant is all electric with anoptional on-board genset.

193

(Model 52S shown)

In some cases, data contained

in the following section

is derived from other sources.

To the best of Kolberg-Pioneer

and JCI’s knowledge, the information

shown is correct.

194

&

Astec companies

195

RAILROAD BALLASTBallast is a relatively coarse aggregate which

provides a stable load carrying base for trackage aswell as quick drainage. Ballast normally would becrushed quarry or slag materials: free of clay, silt, etc.

Two typical specifications follow to provide someidea as to general gradations:

Sieve Example “A” Example “B”Opening Percent Passing Percent Passing

3" (76.2 mm) 100

21⁄2" (63.5 mm) 90 -100 100

2" (50.8 mm) 96 -100

11⁄2" (38.1 mm) 25 - 60 35 - 70

1" (25.4 mm) 0 - 153⁄4" (19.0 mm) 0 - 131⁄2" (12.7 mm) 0 - 5 0 - 5

NOTE: The above are typical. However, there are many other ballast sizesdependent on job specifications. Note also that ballast is most usuallypurchased on a unit volume rather than tonnage basis.

1 sack cement = 1 cu. ft.; 4 sacks = 1 bbl.; 1 bbl. = 376 lbs.

Quantities of Cement, Fine Aggregate and Coarse AggregateRequired for One Cubic Yard of Compact Mortar or Concrete

Mixtures Approx. Quantities of Materials

C.A.F.A. (Gravel Cement

Cement (Sand) or Stone) in Sacks Cu. Ft. Cu. Yd. Cu. Ft. Cu. Yd.

1 1.5 15.5 23.2 0.861 2.0 12.8 25.6 0.951 2.5 11.0 27.5 1.021 3.0 9.6 28.8 1.07

1 1.5 3 7.6 11.4 0.42 22.8 0.851 2.0 2 8.3 16.6 0.61 16.6 0.611 2.0 3 7.0 14.0 0.52 21.0 0.781 2.0 4 6.0 12.0 0.44 24.0 0.89

1 2.5 3.5 5.9 14.7 0.54 20.6 0.761 2.5 4 5.6 14.0 0.52 22.4 0.831 2.5 5 5.0 12.5 0.46 25.0 0.921 3.0 5 4.6 13.8 0.51 23.0 0.85

Fine Aggregate Coarse Aggregate

196

CubicalSize(in.) 145 150 155 160 165 170 175 180 185

5 10 11 11 12 12 12 13 13 136 18 19 19 20 21 21 22 23 237 29 30 31 32 33 34 35 36 378 43 44 46 47 49 50 52 53 559 61 63 65 68 70 72 74 76 7810 84 87 90 93 95 98 101 104 10711 112 116 119 123 127 131 135 139 14212 145 150 155 160 165 170 175 180 18513 184 191 197 203 210 216 222 229 23514 230 238 246 254 262 270 278 286 29415 283 293 302 312 322 332 342 351 36116 344 356 367 379 391 403 415 426 43817 412 426 440 454 469 483 497 511 52618 489 506 523 539 556 573 590 607 62419 575 595 615 634 654 674 694 714 73420 671 694 717 740 763 786 810 833 85622 893 925 954 985 1016 1047 1078 1108 113924 1160 1200 1239 1279 1319 1359 1399 1439 147925 1475 1526 1575 1626 1677 1728 1779 1830 188128 1842 1905 1967 2031 2094 2158 2222 2285 234930 2265 2343 2419 2498 2576 2654 2732 2811 288932 2749 2844 2936 3031 3126 3221 3316 3411 350634 3298 3412 3522 3636 3750 3864 3978 4092 420636 3914 4050 4180 4316 4451 4586 4722 4857 499239 4978 5150 5321 5493 5664 5836 6008 6179 6351

RIPRAP

Weights of Riprap—Pounds

NOTE: The above is given as general information only; each job will carry itsindividual specification.

Solid Rock Density—Lbs. Per Ft.3 (Approx.)

Riprap as used for facing dams, canals and waterwaysis normally a coarse, graded material. Typical generalspecifications would call for a minimum 160 lb./ft.3stone, free of cracks and seams with no sand, clay,dirt, etc. A typical specification will probably give thepercent passing by particle weight such as:

Percent Passing 15" Blanket 24" Blanket

100 165 lbs. 670 lbs.50 - 70 50 lbs. 200 lbs.30 - 50 35 lbs. 135 lbs.0 - 15 10 lbs. 40 lbs.

In order to relate the above weights to rock size, referto the following size/density chart:

1 3.3 14 1⁄2 * 15 1.7 14 1⁄2 * 1511⁄2 4.7 14 1⁄2 * 15 2.4 14 1⁄2 * 152 6 14 1⁄2 * 20 3.0 14 1⁄2 * 15 3 9 14 1⁄2 * 30 4.5 14 1⁄2 * 155 15 12 1⁄2 * 45 7.5 14 1⁄2 * 25

71⁄2 22 8 3⁄4 ✝ 60 11 14 1⁄2 ✝ 3010 27 8 3⁄4 ✝ 70 14 12 1⁄2 ✝ 3515 38 6 11⁄4 ✝ 80 19 10 3⁄4 ✝ 5020 52 4 11⁄4 ✝ 110 26 8 3⁄4 ✝ 7025 64 3 11⁄4 ✝ 150 32 6 11⁄4 ✝ 7030 77 1 11⁄2 ✝ 175 39 6 11⁄4 ✝ 8040 101 00 2 ✝ 200 51 4 11⁄4 ✝ 10050 125 000 2 ✝ 250 63 3 11⁄4 ✝ 12560 149 200,000

C.M. 21⁄2 ✝ 300 75 1 11⁄2 ✝ 15075 180 0000 21⁄2 ✝ 300 90 0 2 ✝ 200100 245 500 3 ✝ 500 123 000 2 ✝ 250125 310 750 31⁄2 ✝ 500 155 0000 21⁄2 ✝ 350150 360 1000 4 ✝ 600 180 300 21⁄2 ✝ 400200 480 240 500 3 ✝ 500250 580 290300 696 348

197

MOTOR WIRING AT STANDARD SPEEDSFrom National Electrical Code

Single-Phase Induction Motors

✝✝ ,** Where high ambient temperature is present it may, in some cases, benecessary to install next larger size thermal overload relay.

3-Phase Squirrel-Cage Induction Motors

✝✝ Min. **Max. ✝✝ Min. **MaxFull Size Size Rating Full Size Size Rating

Load Wire Con- of Load Wire Con- ofHP. Amp. AWG duit Branch Amp. AWG duit Branch

Per Rubber in Circuit Per Rubber in CircuitPhase Covered Inches Fuses Phase Covered Inches Fuses

1⁄2 7 14 1⁄2 25 3.5 14 1⁄2 153⁄4 9.4 14 1⁄2 30 4.7 14 1⁄2 151 11 14 1⁄2 35 5.5 14 1⁄2 20

11⁄2 15.2 12 1⁄2 45 7.6 14 1⁄2 252 20 10 3⁄4 60 10 14 1⁄2 303 28 8 3⁄4 90 14 12 1⁄2 455 46 4 11⁄4 150 23 8 3⁄4 70

71⁄2 34 6 1 11010 43 5 11⁄4 125

120 Volts 230 Volts

230 Volts 460 Volts

‡‡

‡‡‡

1 8.4 14 1⁄2 15 4.2 14 1⁄2 1511⁄2 12.5 12 1⁄2 20 6.3 14 1⁄2 152 16.1 10 3⁄4 25 8.3 14 1⁄2 153 23 8 3⁄4 35 12.3 12 1⁄2 205 40 6 1 60 19.8 10 3⁄4 30

71⁄2 58 3 11⁄4 90 28.7 6 1 4510 75 1 11⁄2 125 38 6 1 6015 112 00 2 175 56 4 11⁄4 9020 140 000 2 225 74 1 11⁄2 12525 184 300 21⁄2 300 92 0 2 15030 220 400 3 350 110 00 2 17540 292 700 31⁄2 450 146 0000 21⁄2 22550 360 1000 4 600 180 300 21⁄2 30060 215 400 3 35075 268 600 31⁄2 450100 355 1000 4 600

Horsepower 1800 RPM 1200 RPM2 145T 184T3 182T 213T5 184T 215T

71⁄2 213T 254T10 215T 256T

15 254T 284T20 256T 286T25 284T 324T30 286T 326T40 324T 364T

50 326R 365T60 364T 404T75 365T 405T

198

MOTOR WIRING AT STANDARD SPEEDS, (Continued)

From National Electrical Code

DIRECT CURRENT MOTORS

NEMA Frame Numbers for Polyphase Induction Motors

✝✝ Min. **Max. ✝✝ Min. **MaxFull Size Size Rating Full Size Size Rating

Load Wire Con- of Load Wire Con- ofHP. Amp. AWG duit Branch Amp. AWG duit Branch

Per Rubber in Circuit Per Rubber in CircuitPhase Covered Inches Fuses Phase Covered Inches Fuses

115 Volts

“T” Frame

230 Volts

‡‡‡‡

‡‡‡‡

M.C.M.In order to avoid excessive voltage drop where long runs are involved, it may benecessary to use conductors and conduit of sizes larger than the minimum sizes listedabove.Branch-circuit fuses must be large enough to carry the starting current, hence theyprotect against short-circuit only. Additional protection of an approved type must beprovided 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 forfull-voltage starting of high-reactance, low starting current squirrel-cage motors.

‡✝✝

**

*✝

199

DIMENSIONS, IN INCHES, OF ELECTRIC MOTORSBy NEMA Frame Number

M + N D E F U V Keyway

182T 73⁄4 41⁄2 33⁄4 21⁄4 11⁄8 21⁄2 1⁄4 x 1⁄8184T 81⁄4 41⁄2 33⁄4 23⁄4 11⁄8 21⁄2 1⁄4 x 1⁄8213 91⁄4 51⁄4 41⁄4 23⁄4 11⁄8 23⁄4 1⁄4 x 1⁄8213T 95⁄8 51⁄4 41⁄4 23⁄4 13⁄8 31⁄8 5⁄16 x 5⁄32

215 10 51⁄4 41⁄4 31⁄2 11⁄8 23⁄4 1⁄4 x 1⁄8215T 103⁄8 51⁄4 41⁄4 31⁄2 13⁄8 31⁄8 5⁄16 x 5⁄32

254T 123⁄8 61⁄4 5 41⁄8 15⁄8 33⁄4 3⁄8 x 3⁄16

254U 121⁄8 61⁄4 5 41⁄8 13⁄8 31⁄2 5⁄16 x 5⁄32

256T 131⁄4 61⁄4 5 5 15⁄8 33⁄4 3⁄8 x 3⁄16

256U 13 61⁄4 5 5 13⁄8 31⁄2 5⁄16 x 5⁄32

284T 141⁄8 7 51⁄2 43⁄4 17⁄8 43⁄8 1⁄2 x 1⁄4284U 143⁄8 7 51⁄2 43⁄4 15⁄8 45⁄8 3⁄8 x 3⁄16

286T 147⁄8 7 51⁄2 51⁄2 17⁄8 43⁄8 1⁄2 x 1⁄4286U 151⁄8 7 51⁄2 51⁄2 15⁄8 45⁄8 3⁄8 x 3⁄16

324T 153⁄4 8 61⁄4 51⁄4 21⁄8 5 1⁄2 x 1⁄4324U 161⁄8 8 61⁄4 51⁄4 17⁄8 53⁄8 1⁄2 x 1⁄4326T 161⁄2 8 61⁄4 6 21⁄8 5 1⁄2 x 1⁄4326U 167⁄8 8 61⁄4 6 17⁄8 53⁄8 1⁄2 x 1⁄4364T 173⁄8 9 7 55⁄8 23⁄8 55⁄8 5⁄8 x 5⁄16

364U 177⁄8 9 7 55⁄8 21⁄8 61⁄8 1⁄2 x 1⁄4365T 177⁄8 9 7 61⁄8 23⁄8 55⁄8 5⁄8 x 5⁄16

365U 183⁄8 9 7 61⁄8 21⁄8 61⁄8 1⁄2 x 1⁄4404T 20 10 8 61⁄8 27⁄8 7 3⁄4 x 3⁄8404U 197⁄8 10 8 61⁄8 23⁄8 67⁄8 5⁄8 x 5⁄16

405T 203⁄4 10 8 67⁄8 27⁄8 7 3⁄4 x 3⁄8405U 205⁄8 10 8 67⁄8 23⁄8 67⁄8 5⁄8 x 5⁄16

444U 233⁄8 11 9 71⁄4 27⁄8 83⁄8 3⁄4 x 3⁄8445U 243⁄8 11 9 81⁄4 27⁄8 83⁄8 3⁄4 x 3⁄8

200

AWG Amp Amp Diameter Amp* DiameterSize Capacity 2 Cond. 3 Cond. 4 Cond. Capacity (Inches) Capacity (Inches)

250 MCM 275 2.394/0 245 2.04 210 2.263/0 220 1.89 190 2.072/0 190 1.75 170 1.931/0 160 1.65 145 1.791 145 1.51 125 1.682 130 1.34 110 1.483 110 1.24 95 1.344 95 1.17 85 1.276 75 1.01 60 1.108 55 0.91 50 0.9910 25 .640 .690 .75012 20 .605 .640 .67014 15 .530 .560 .60516 10 .405 .430 .48518 7 .390 .405 .435

CURRENT CARRYING CAPACITIES AND CABLE DIAMETER SIZES FOR THE PORTABLE CABLES

Diameter (Inches)

Type SO Cord 3 Conductor Type “G” 4 Conductor Type “W”

*When using 4 conductor type “W” cable on 3 phase circuit with 4th conductor used asground, use amp capacity for 3 conductor type “G” cable.

Above Data from Western InsulatedWire Co. fro Bronco 66 Certified Cable

201

GENERATOR SIZE TO POWERELECTRIC MOTORS ON CRUSHING

AND SCREENING PLANTSThe minimum generator size to power a group ofmotors should be selected on the basis of the fol-lowing rules which allow all motors to operatesimultaneously with complete freedom of startingsequence.

A. GENERATOR KW—0.8 x total electric nameplate horsepower.

B. GENERATOR KW—2 x name plate horse-power of the largest electric motor withacross-the-line starter.

C. GENERATOR KW—1.5 x name plate horse-power of the largest electric motor withreduced voltage starting (with 80 percent start-ing voltage).

D. GENERATOR KW—2.25 x name plate horse-power of the largest electric motor with partwinding starting.

For across-the-line starting, use the larger of thetwo values determined from A and B.

For reduced voltage starting, use the larger of thetwo values determined from A and C.

For part winding starting, use the larger of the twovalues determined from A and D.

For combinations of the above starting types, usethe largest value determined from A, B, C, and Das they apply.

202

DREDGE PUMP

Above information can be used as a guide in pre-liminary selection of material handlingcomponents. For plants charged by dredgepumps. Proper selection of sand processingcomponents is in part controlled by maximumamount of water in the slurry.

Prior to final selection of machinery, completeinformation must be assimilated so sound judge-ment can be exercised.

SIZE SLURRY GPM TPH

4 680 38

6 1,500 85

8 2,700 153

10 4,100 233

12 5,900 335

14 7,300 414

16 9,670 550

18 12,280 696

20 15,270 866

20% Solids @ 100 lb./cu. ft.

(% Solids by Weight)

NOTE: GPM ÷ 17.6 = TPHTPH X 17.6 = GPM

203

VELOCITY OF FLOW IN PIPES

4000

3000

2500

2000

1500

1000900800700

600

500

400

300

200

150

10090807060

50

40

30

25

20

4000

3000

2500

2000

1500

1000900800700

600

500

400

300

200

150

10090807060

50

40

30

25

203 4 5 6 7 8 9 10 11 12 13 14 15 16 17

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

VELOCITY - FEET PER SECOND

VELOCITY - FEET PER SECOND

STDPIPESIZE

1"

2"

3"

4"

5"

6"

8"

10"

12"

1-1/4"

1-1/2"

2-1/2"

NOTE: Based on following ID’s for Std. Wt. W:I or Steel Pipe

1" . . . . . 1.049" 21⁄2" . . . . 2.469" 6" . . . . . 6.065"11⁄4" . . . . 1.380" 3". . . . . . 3.068" 8" . . . . . 7.981"11⁄2" . . . . 1.610" 4". . . . . . 4.026" 10" . . . 10.020"2" . . . . . 2.067" 5". . . . . . 5.047" 12" . . . 11.938"

204

FRICTION LOSS IN PIPES

NOTE: Based on new, Standard Weight Wrought Iron or Steel Pipe.

10.1 .2 .3 .4 .5 .6 .8 2 3 4 5 6 8 10 20 30 40 501.0

.1 .2 .3 .4 .5 .6 .8 2 3 4 5 6 8 10 20 30 40 501.0

20

30

40

50607080

100

100

200

300

400

500600700800

1000

1000

2000

3000

4000

5000

10

20

30

40

50607080

100

100

200

300

400

500600700800

1000

1000

2000

3000

4000

5000

FRICTION LOSS FOR WATER IN FEET OF HEAD PER 100 FT. PIPE

FRICTION LOSS FOR WATER IN FEET OF HEAD PER 100 FT. PIPE

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

U.S

. GA

LL

ON

S P

ER

MIN

UT

E

12"12"

10"10"

8"8"

6"6"

5"5"

4"4"

3"3"

2-1/2"2-1/2"

2"2"

1-1/2"1-1/2"

1-1/4"1-1/4"

1"1"

205

FLOW OVER WEIRSSettling Tanks, Classifiers, Sand Preps, Flumes

GENERALMeasure overflow depth (h) at a distance back of weirat least four times h. Use a flat strip taped to the end ofa carpenter’s level.

Multiply figure from curve by length of weir.

FLUME OR LAUNDERUse a bevel-edge steel plate or board with sharp edgeupstream.

L(Weir length) and D (depth of water behind weir) musteach be at least three times h.

Water or slurry must fall free of weir; i.e., with air spaceunderneath. If possible, drill air holes in side of launderon downstream side of weir plate.

Curve does not apply to triangular or notched weirs.

250

1

2

3

4

5

0

1

2

3

4

5

50 75 100 150 200 250 300 400

25 50 75 100 150 200 250 300 400

GPM OVERFLOW PER FOOT OF WEIR

OV

ER

FL

OW

DE

PT

H (

H)

IN IN

CH

ES

OV

ER

FL

OW

DE

PT

H (

H)

IN IN

CH

ES

GPM OVERFLOW PER FOOT OF WEIR

Settling Tanks, Classifiers, Sand Preps, Flumes

206

SPRAY NOZZLESFOR VIBRATING SCREENS

The introduction of water under pressure over thevibrating screens often greatly improvesscreening efficiency as well as aiding in theremoval of deleterious materials on the individualaggregate particles. KOLBERG utilizes Type WFFlat Spray Nozzles over the screens to produce auniform, flat spray pattern without hard edges atpressures of 5 psi and up. Tapered edges of thespray pattern permits pattern overlap with evendistribution of the spray. The impact of spray isgenerally greater with narrower spray angles,assuming the same flow rate.

AVAILABLE SPRAY ANGLESNozzle Size

0° — All sizes15° — All sizes thru WF 15025° — All sizes thru WF 15040° — All sizes thru WF 15050° — All sizes thru WR 20065° — All sizes80° — All sizes90° — All sizes thru WF 250

TYPE WF CAPACITY CHARTNozzle Number—Capacity at 40 PSI

SHADED COLUMNS INDICATE MOST AVAILABLE SIZES.

NOZZLE Equiv.NUMBER Orif. PIPE SIZE CAPACITY — GPM AT PSI PRESSURE

Male No. Dia. 1⁄8 1⁄4 3⁄8 1⁄2 3⁄4 40 60 80 100 150 200 300 400 500 600 700 800 1000

WFM 2 .034 .20 .24 .28 .32 .39 .45 .55 .63 .71 .77 .84 .89 1.0

WFM 4 .052 .40 .49 .57 .63 .77 .89 1.1 1.3 1.4 1.6 1.7 1.8 2.0

WFM 4.5 .055 .45 .55 .64 .71 .87 1.0 1.2 1.4 1.5 1.7 1.9 2.0 2.2

WFM 5 .057 .50 .61 .71 .79 .97 1.1 1.4 1.6 1.8 1.9 2.1 2.2 2.5

WFM 5.5 .060 .55 .67 .78 .87 1.1 1.2 1.5 1.7 1.9 2.1 2.3 2.5 2.8

WFM 6 .062 .60 .73 .85 .95 1.2 1.3 1.6 1.9 2.1 2.3 2.5 2.7 3.0

WFM 6 .064 .65 .80 .92 1.0 1.3 1.5 1.8 2.1 2.3 2.5 2.7 2.9 3.3

WFM 7 .067 .70 .86 .99 1.1 1.4 1.6 1.9 2.2 2.5 2.7 2.9 3.1 3.5

WFM 8 .072 .80 .98 1.1 1.3 1.5 1.8 2.2 2.5 2.8 3.1 3.4 3.6 4.0

WFM 8.5 .074 .85 1.1 1.2 1.3 1.6 1.9 2.3 2.7 3.0 3.3 3.6 3.8 4.2

WFM 9 .076 .90 1.1 1.3 1.4 1.7 2.0 2.5 2.8 3.2 3.5 3.8 4.0 4.5

WFM 10 .080 1.0 1.2 1.4 1.6 1.9 2.2 2.7 3.2 3.5 3.9 4.2 4.5 5.0

207

TYPE WF CAPACITY CHART—Nozzle Number—Capacity at 40 PSI

SHADED COLUMNS INDICATE MOST AVAILABLE SIZES.

208

NOZZLE Equiv.NUMBER Orif. PIPE SIZE CAPACITY — GPM AT PSI PRESSURE

Male No. Dia. 1⁄8 1⁄4 3⁄8 1⁄2 3⁄4 10 15 20 30 40 60 80 100 150 200 300 400 500

WFM* 15 3⁄32 .75 .92 1.1 1.3 1.5 1.8 2.1 2.4 2.9 3.4 4.1 4.7 5.3

WFM 20 7⁄64 1.0 1.2 1.4 1.7 2.0 2.5 2.8 3.2 3.9 4.5 5.5 6.3 7.1

WFM 30 9⁄64 1.5 1.8 2.1 2.6 3.0 3.7 4.2 4.7 5.8 6.7 8.2 9.5 10.6

WFM 40 5⁄32 2.0 2.5 2.8 3.5 4.0 4.9 5.7 6.3 7.7 9.0 11.0 12.7 14.2

WFM 50 11⁄64 2.5 3.1 3.5 4.3 5.0 6.1 7.1 7.9 9.7 11.2 13.7 15.8 17.7

WFM 60 3⁄16 3.0 3.7 4.2 5.2 6.0 7.3 8.5 9.5 11.6 13.4 16.4 19.0 21.2

WFM* 70 13⁄64 3.5 4.3 4.9 6.1 7.0 8.6 9.9 11.1 13.5 15.7 19.2 22.2 24.8

WFM 80 7⁄32 4.0 5.0 5.6 5.8 8.0 9.8 11.4 12.6 15.4 17.9 21.9 25.3 28.3

WFM 100 1⁄4 5.0 6.1 7.1 8.6 10.0 12.2 14.1 15.8 19.4 22.3 27.4 31.6 35.3

WFM 150 19⁄64 7.5 9.2 10.6 13.0 15.0 18.4 21.2 23.7 29.0 33.5 41.1 47.4 53.1

WFM 200 11⁄32 10.0 12.2 14.1 17.3 20.0 24.5 28.3 31.6 38.7 44.3 54.7 63.3 70.8

WFM 250 25⁄64 12.5 15.7 17.7 21.6 25.0 30.5 35.4 39.4 48.4 55.8 68.4 79.0 88.4

WFM 300 27⁄64 15.0 18.4 21.2 26.0 30.0 36.8 42.4 47.4 58.0 66.9 82.1 94.8 106.0

WFM 400 1⁄2 20.2 24.4 28.2 34.6 40.0 49.0 56.6 63.2 77.4 89.5 110.0 127.0 141.0

209

DIMENSIONS AND WEIGHTS FOR TYPE WF

WATER VOLUME REQUIRED FOR WASHINGAGGREGATESThe amount of water required for washing aggregates underaverage conditions is 3 to 5 GPM of water for each TPH ofmaterial fed to a washing screen. The finer the feedgradation, the more GPM of water required.

GETTING MAXIMUM WASHED PRODUCTFROM A VIBRATING SCREENScreen efficiency can be greatly increased by applying waterdirectly to the feed box located ahead of the vibrating screen.Water volume applied must be sufficient to form a slurry inthe feed box so that effective screening begins immediatelywhen the wet product contacts the screen.

DIMENSIONS (Inches)PIPE WEIGHTSIZE TYPE A B C (Ounces)

1⁄8 WFM 11⁄167⁄16

5⁄16 .41⁄4 WFM 31⁄32

9⁄163⁄8 .7

3⁄8 WFM 1 11⁄167⁄16 1.1

1⁄2 WFM 117⁄647⁄8 1⁄2 2.5

3⁄4 WFM 127⁄6411⁄16

5⁄8 5.0

210

WEIGHTS AND MEASURES—UNITED STATES

Linear Measure

8 furlongs80 chains

1 mile = 320 rods1760 yards5280 feet10 chains

1 furlough = 220 yards6.06 rods

1 station = 33.3 yards100 feet

4 rods22 yards

1 chain = 66 feet100 links5.5 yards

1 rod = 16.5 feet3 feet

1 yard = 36 inches1 foot = 12 inches

1 link = 7.92 inches1 statute mile = 80 chains

100 links1 chain = 4 rods

66 feet22 yards

Gunter’s or Surveyor’s Chain Measure

36 sections1 township = 36 sq. miles

1 section1 sq. mile = 640 acres

4,840 sq. yards1 acre = 43,560 sq. feet

160 sq. rods

2721⁄4 sq. feet1 sq. rod = 301⁄4 sq. yards

1,296 sq. inches1 sq. yard = 9 sq. feet1 sq. foot = 144 sq. inches

Land Measure

1 cubic yard = 27 cubic feet1 cord (wood) = 4x4x8 ft. = 128 cu. ft.1 ton (shipping) = 40 cubic ft.

1 cu. ft. = 1728 cu. in.1 bushel = 2150.42 cu. in.1 gallon = 231 cu. in.

Cubic Measure

1 long ton = 2250 lbs.1 short ton = 2000 lbs.

1 pound = 16 ounces1 ounce = 16 drams

Weights (Commercial)

12 ounces1 pound = 5760 grains

20 pennyweights1 ounce = 480 grains

Troy Weight (For Gold and Silver)

1 pennyweight = 24 grains

= 4 gills (gl.)1 pint (pt.) = 28.875 cu. in.

= 2 pints1 quart (qt.) = 57.75 cu. in.

4 quarts8 pints

1 gallon (gal.) = 32 gills231 cu. in.81⁄2 lbs. @ 62°F

1 hogshead = 63 gallons1 barrel = 311/2 gallons1 cu. ft. 7.48 U.S. gals.water = 1728 cu. in.

621⁄2 lbs. @ 62°F

Liquid Measure

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211

WEIGHTS AND MEASURES—UNITED STATES

Dry Measure

2 pints (pt.)1 quart (qt.) = 67.20 cu. in.

8 quarts1 peck (pk.) = 16 pints

537.605 cu. in.

4 pecks1 bushel (bu. ) = 32 quarts

2150.42 cu. in.

(When necessary to distinguish the dry pint or quart from the liquid pint orquart, the word “dry” should be used in combination with the name or abbre-viation of the dry unit.)

1 fathom = 6 feet1 cable length = 120 fathoms1 nautical mile = 6,080 feet

1 marine league = 3 marine miles71⁄2 cable lengths

1 statute mile = 5,280 feet

Mariner’s Measure

.0236 horsepower17.6 watts

1 BTU per minute = .0176 kilowatts778 foot lbs. per min.

.0226 watts1 ft. lb. per minute = .001285 BTU per min.

746 watts.746 kilowatts

1 horsepower = 33,000 ft. lbs. per min.42.4 BTU per min.

.00134 horsepower1 watt = .001 kilowatts

44.2 ft. lbs. per min..0568 BTU per min.1.341 horsepower

1 kilowatt = 1000 watts44.250 ft. lbs. per min.

56.8 BTU per min.

Measures of Power

1 sq. centimeter = 100 sq. milli-(cm2) meters (mm2)

1,000,000 mm2

1 sq. meter (m2) = 10,000 cm2

1 are (a) = 100 m2

10,000 m2

1 hectare (ha) = 100 a1 sq. kilometer = 1,000,000 m2

(km2) 100 ha

WEIGHTS AND MEASURES—METRICArea Measure

1 centimeter (cm)= 10 milli-meters (mm)100 mm

1 decimeter (dm) = 10 cm1,000 mm

1 meter (m) = 10 dm

1 dekameter (dkm) = 10 m100 m

1 hectometer (hm) = 10 dkm1,000 m

1 kilometer (km) = 10 hm

Linear Measure

1 centigram (cg) = 10 milligrams(mg)

100 mg1 decigram (dg) = 10 cg

1,000 mg1 gram (g) = 10 dg.

100g1 hectogram (hg) = 10 dkg1 dekagram (dkg) = 10 g

1,000 g1 kilogram (kg) = 10 hg1 metric ton (1) = 1,000 kg

Weight

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212

WEIGHTS AND MEASURES—METRIC (Continued)

Cubic Measure1 cubic centimeter (cm3) = 1,000 cubic millimeters (mm3)

1,000,000 mm3

1 cubic decimeter (dm3) = 1,000 cm3

1 stere1,000,000,000 mm3

1 cubic meter (m3) = 1,000,000 cm3

1,000 dm3

METRIC-U.S. CONVERSION FACTORS(Based on National Bureau of Standards)

Sq. cm. x 0.1550 = sq. ins. Sq. ins. x 6.4516 = sq. cmSq. m. x 10.7639 = sq. ft. Sq. ft. x 0.0929 = sq. mAres x 1076.39 = sq. ft. Sq. ft. x 0.00093 = aresSq. m x 1.1960 = sq. yds. Sq. yds. x 0.8361 = sq. mHectare x 2.4710 = acres Acre x 0.4047 = hectaresSq. km x 0.3861 = sq. miles Sq. miles x 2.5900 = sq. km

1 centiliter (cl) = 10 milliliters (ml)100 ml

1 deciliter (dl) = 10 cl1,000 ml

1 liter* (l) = 10 dl

1 dekaliter (dkl) = 10 l100 l

1 hectoliter (hl) = 10 dkl1,000 l

1 kiloliter (kl) = 10 hl

Volume Measure

.986 U.S. horsepower1 metric horsepower = 736 watts 32,550 ft. lbs. per min.

.736 kilowatts 41.8 BTU per min.

Power

*The liter is defined as the volume occupied, under standard conditions, by a quantity ofpure water having a mass of 1 kilogram.

Area

Kgs per sq. cm x 14.223 = lbs. per sq. in.Lbs. per sq. in. x 0.0703 = kgs per sq. cmKgs per sq. in. x 0.2048 = lbs. per sq. ft.Kgs per sq. m x .204817 = lbs. per sq. ft.Lbs. per sq. ft. x 4.8824 = kgs per sq. mKgs per sq. m x .00009144 = tons (long) per sq. ft.

Pressure

Centimeters x 0.3937 = inches Inches x 2.5400 = centimetersMeters x 3.2808 = feet Feet x 0.3048 = metersMeters x 1.0936 = yards Yards x 0.9144 = metersKilometers x 0.6214 = miles* Miles* x 1.6093 = kilometersKilometers x 0.53959 = miles** Miles** x 1.85325 = kilometers

*Statute miles **Nautical miles

Length

Cu. ft. per min. x 0.028314 = cu. m per min.Cu. m per min. x 35.3182 = cu. ft. per min.

Flow

Metric horsepower x .98632 = U.S. horsepowerU.S. horsepower x 1.01387 = metric horsepower

Power

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213

Tons (long) per sq. ft. x 10940.0 = kg per sq. mKgs per sq. mm x .634973 = tons (long) per sq. in.Tons (long) per sq. in. x 1.57494 = kg per sq. mmKgs per cu. m x .062428 = lbs. per cu. ft.Lbs. per cu. ft x 16.0184 = kgs per cu. mKgs per m x .671972 = lbs. per ft.Lbs. per ft. x 1.48816 = kgs per mKg/m x 7.233 = ft. lbs.Ft. lbs. x .13826 = kg/mKgs per sq. com x 0.9678 = normal atmosphereNormal atmosphere x 1.0332 = kgs per sq cm

Board feet x 144 sq. in. x 1 in. = cubic inchesBoard feet x .0833 = cubic feetCubic feet x 6.22905 = gallons, Br. Imp.Cubic feet x 2.38095 x 10-2 = tons, Br. shippingCubic feet x .025 = tons, U.S. shippingDegrees, angular x .0174533 = radiansDegrees, F. (less 32°F) x .5556 = degrees, CentigradeDegrees, centigrade x 1.8 plus 32 = degrees, F.Gallons, Br. Imp. x .160538 = cubic feetGallons, Br. Imp. x 4.54596 = litersGallons, U.S. x .13368 = cubic feetGallons, U.S. x 3.78543 = litersLiters x .219975 = gallons, Br. Imp.Miles, statute x .8684 = miles, nauticalMiles, nautical x 1.1516 = miles, statuteRadians x 57.29578 = degrees, angularTons, long x 1.120 = tons, shortTons, short x .892857 = tons, longTons, Br. shipping x 42.00 = cubic feetTons, Br. shipping x .952381 = tons, U.S. shippingTons, U.S. shipping x 40.00 = cubic feetTons, U.S. shipping x 1.050 = tons, Br. shipping

Note: Br. Imp = British Imperial

METRIC-U.S. CONVERSION FACTORS (Continued)

Pressure (Continued)

Grams x 15.4324 = grains Grains x 0.0648 = gGrams x 0.0353 = oz. Oz. x 28.3495 = gGrams x 0.0022 = lbs. Lbs. x 453.592 = gKgs x 2.2046 = lbs. Lbs. x 0.4536 = kgKgs x 0.0011 = tons (short) Lbs. x 0.0004536 = tons*Kgs x 0.00098 = tons (long) Tons (short) x 907.1848 = kgTons* x 1.1023 = ton (short) Tons (short) x 0.9072 = tons*Tons* x 2204.62 = lbs. Tons (long) x 1016.05 = kg

Weight

Cu. cm. x 0.0610 = cu. in. Cu. ins. x 16.3872 = cu. cmCu. m x 35.3145 = cu. ft. Cu. ft. x 0.0283 = cu. mCu. m x 1.3079 = cu. yds. Cu. yds. x 0.7646 = cu. mLiters x 61.0250 = cu. in. Cu. ins. x 0.0164 = litersLiters x 0.0353 = cu. ft. Cu. ft. x 27.3162 = litersLiters x 0.2642 = gals. (U.S.) Gallons x 3.7853 = litersLiters x 0.0284 = bushels (U.S.) Bushels x 35.2383 = liters

Volume

Miscellaneous Conversion Factors

1000.027 = cu. cmLiters x 1.0567 = qt. (liquid) or 0.9081 = qt. (dry)

2.2046 = lb. of pure water at 4°C = 1 kg.{

214

APPROXIMATE WEIGHT OF MATERIALSWeight, Weight, Weight,

MATERIAL lbs./ft3 lbs./yd3 kg./m3

Andesite, Solid . . . . . . . . . . . . . . . . . . . . . . . 173 4,660 2,771Ashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 1,100 657Basalt, Broken . . . . . . . . . . . . . . . . . . . . . . . . 122 3,300 1954Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 5,076 3012

Caliche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2,430 1442Cement, Portland . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Mortar, Portland, 1:21⁄2 . . . . . . . . . . . . . . . . 135 3,654 2162

Cinders, Blast Furnace. . . . . . . . . . . . . . . . . . 57 1,539 913Coal, Ashes and Clinkers. . . . . . . . . . . . . . . 40 1,080 641

Clay, Dry Excavated. . . . . . . . . . . . . . . . . . . . 68 1,847 1089Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . 114 3,080 1826Dry Lumps . . . . . . . . . . . . . . . . . . . . . . . . . 67 1,822 1073Wet Lumps . . . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Compact, Natural Bed . . . . . . . . . . . . . . . . . 109 2,943 1746

Clay and Gravel, Dry . . . . . . . . . . . . . . . . . . . 100 2,700 1602Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 3,085 1826

Concrete, Asphaltic . . . . . . . . . . . . . . . . . . . . 140 3,780 2243Gravel or Conglomerate . . . . . . . . . . . . . . . 150 4,050 2403Limestone with Portland Cement . . . . . . . . 148 3,996 2371

Coal, Anthracite, Natural Bed. . . . . . . . . . . . . 94 2,546 1506Broken. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 1,857 1105Bituminous, Natural Bed . . . . . . . . . . . . . . . 84 2,268 1346Broken. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 1,413 833

Cullett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100 2,160-2,700 1281-1602Dolomite, Broken . . . . . . . . . . . . . . . . . . . . . 109 2,940 1746Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 4,887 2809

Earth, Loam, Dry Excavated . . . . . . . . . . . . . 78 2,100 1249Moist Excavated . . . . . . . . . . . . . . . . . . . . . 90 2,430 1442Wet Excavated. . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Dense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3,375 2002Soft Loose Mud. . . . . . . . . . . . . . . . . . . . . . 108 2,196 1730Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 2,565 1522

Gneiss, Broken . . . . . . . . . . . . . . . . . . . . . . . 116 3,141 1858Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 4,833 2,867

Granite, Broken or Crushed. . . . . . . . . . . . . . 103 2,778 1650Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 4,525 2691

Gravel, Loose, Dry. . . . . . . . . . . . . . . . . . . . . 95 2,565 1522Pit Run, (Gravelled Sand) . . . . . . . . . . . . . . 120 3,240 1922Dry 1⁄4 - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . 105 2,835 1682Wet 1⁄2 - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3,375 2002

Gravel, Sand & Clay, Stabilized, Loose . . . . . 100 2,700 1602Compacted . . . . . . . . . . . . . . . . . . . . . . . . . 150 4,050 2403

Gypsum, Broken . . . . . . . . . . . . . . . . . . . . . . 113 3,054 1810Crushed. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 4,698 2787

Halite (Rock Salt) Broken . . . . . . . . . . . . . . . 94 2,545 1506Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 3,915 2323

Hematite, Broken. . . . . . . . . . . . . . . . . . . . . . 201 5,430 3220Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 8,262 4902

Limonite, Broken. . . . . . . . . . . . . . . . . . . . . . 154 4,159 2467Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 6,399 3028

Limestone, Broken or Crushed . . . . . . . . . . . 97 2,625 1554Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 4,400 2611

Magnetite, Broken . . . . . . . . . . . . . . . . . . . . . 205 5,528 3,284Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 8,505 5046

Marble, Broken . . . . . . . . . . . . . . . . . . . . . . . 98 2,650 1570Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 4,308 2563

Marble Wet Excavated . . . . . . . . . . . . . . . . . . 140 3,780 2243Mica, Broken . . . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 4,860 2883

215

APPROXIMATE WEIGHT OF MATERIALSWeight, Weight, Weight,

MATERIAL lbs./ft3 lbs./yd3 kg./m3

Mud, Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 2,916 1730Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 3,200 1906Dry Close . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110 2,160-32,970 1282-1762

Peat, Dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 675 400Moist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 1,350 801Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 1,890 1121

Phosphate Rock, Broken . . . . . . . . . . . . . . . . 110 2,970 1762Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.7 1,936 1148Plaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 1,431 848Porphyry, Broken . . . . . . . . . . . . . . . . . . . . . 103 2,790 1650Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 4,293 2547

Sandstone, Broken . . . . . . . . . . . . . . . . . . . . 94 2,550 1506Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 3,915 2323

Sand, Dry Loose . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Slightly Damp . . . . . . . . . . . . . . . . . . . . . . . 120 3,240 1922Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 3,500 2082Wet Packed . . . . . . . . . . . . . . . . . . . . . . . . . 130 3,510 2082

Sand and Gravel, Dry . . . . . . . . . . . . . . . . . . 108 2,916 1730Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3,375 2022

Shale, Broken . . . . . . . . . . . . . . . . . . . . . . . . 99 2,665 1586Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 4,500 2675

Slag, Broken . . . . . . . . . . . . . . . . . . . . . . . . . 110 2,970 1762Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 3,564 2114

Slag, Screenings . . . . . . . . . . . . . . . . . . . . . . 92 2495 1474Slag, Crushed (3⁄4") . . . . . . . . . . . . . . . . . . . . 74 1,998 1185Slag, Furnace, Granulated . . . . . . . . . . . . . . . 60 1,620 961Slate, Broken. . . . . . . . . . . . . . . . . . . . . . . . . 104 2,800 1666Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 4,535 2,691

Stone, Crushed . . . . . . . . . . . . . . . . . . . . . . . 100 2,700 1602Taconite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 4,050-5,400 2403-3204Talc, Broken . . . . . . . . . . . . . . . . . . . . . . . . . 109 2,931 1746Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 4,535 2691

Tar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.6 1,936 1148Trap Rock, Broken. . . . . . . . . . . . . . . . . . . . . 109 2,950 1746Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 4,870 2883

NOTE: The above weights may vary in accordance with moisture content, texture; etc.

MISCELLANEOUS USEFUL INFORMATIONArea of circle: Multiply square of diameter by .7854.Area of rectangle: Multiply length by breadth.Area of triangle: Multiply base by 1⁄2 perpendicular height.Area of ellipse: Multiply product of both diameters by .7854.Area of sector of circle: Multiply arc by 1⁄2 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 1⁄3 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 1⁄2 height.Diameter of circle: Multiply circumference by .31831.

216

APPROXIMATE WEIGHTS IN POUNDS PER CUBIC YARDOF COMMON MINERAL AGGREGATES WITH VARIOUS

PERCENTAGES OF VOIDS(SPECIFIC GRAVITY OF 1 = APPROX. 1685 LBS.)

SpecificMaterial Gravity 25% 30% 35% 40% 45% 50%

2.8 3540 3300 3070 2830 2600 2360Trap 2.9 3660 3420 3180 2930 2690 2440Rock 3.0 3790 3540 3290 3030 2780 2530

3.1 3910 3650 3390 3130 2870 2610

Granite 2.6 3280 3060 2850 2630 2410 2190and 2.7 3410 3180 2960 2730 2500 2270

Limestone 2.8 3540 3300 3070 2830 2600 2360

2.4 3030 2830 2630 2420 2020 20202.5 3160 2950 2740 2520 2310 2100

Sandstone 2.6 3280 3060 2850 2630 2410 21902.7 3410 3180 2960 2730 2500 2270

2.0 2530 2360 2190 2020 1850 16802.1 2650 2470 2300 2120 1950 17702.2 2780 2590 2410 2220 2040 1850

Slag 2.3 2900 2710 2520 2320 2120 19402.4 3030 2830 2630 2420 2220 20202.5 3160 2950 2740 2520 2310 2100

GranulatedSlag 1.5 1890 1770 1640 1510 1390 1260

GravelSand 2.65 3350 3120 2900 2680 2450 2230

Percentage of Voids

NOTE: Most limestone, gravel and sand will absorb one percent or morewater by weight. Free water in moist sand approximates two percent,moderately wet 4 percent, and very wet seven percent.

DUMPING ANGLESAngles 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°

217

DECIMAL EQUIVALENTS OF FRACTIONS

Inch mm Inch mm

1⁄64 .39687 .015625 33⁄64 13.097 .5156251⁄32 .79375 .03125 17⁄32 13.494 .531253⁄64 1.1906 .046875 35⁄64 13.891 .5468751⁄16 1.5875 .0625 9⁄16 14.287 .5625

5⁄64 1.9844 .078125 37⁄64 14.684 .5781253⁄32 2.3812 .09375 19⁄32 15.081 .593757⁄64 2.7781 .109375 39⁄64 15.478 .6093751⁄8 3.1750 .125 5⁄8 15.875 .625

9⁄64 3.5719 .140625 41⁄64 16.272 .6406255⁄32 3.9687 .15625 21⁄32 16.669 .6562511⁄64 4.3656 .171875 43⁄64 17.066 .6718753⁄16 4.7625 .1875 11⁄16 17.462 .6875

13⁄64 5.1594 .203125 45⁄64 17.859 .7031257⁄32 5.5562 .21875 23⁄32 18.256 .7187515⁄64 5.931 .234375 47⁄64 18.653 .7343751⁄4 6.3500 .25 3⁄4 19.050 .75

17⁄64 6.7469 .265625 49⁄64 19.447 .7656259⁄32 7.1437 .28125 25⁄32 19.844 .7812519⁄64 7.5406 .296875 51⁄64 20.241 .7968755⁄16 7.9375 .3125 13⁄16 20.637 .8125

21⁄64 8.3344 .328125 53⁄64 21.034 .82812511⁄32 8.7312 .34375 27⁄32 21.431 .8437523⁄64 9.1281 .359375 55⁄64 21.828 .8593753⁄8 9.5250 .375 7⁄8 22.225 .875

25⁄64 9.9219 .390626 57⁄64 22.622 .89062513⁄32 10.319 .40625 29⁄32 23.019 .9062527⁄64 10.716 .421875 59⁄64 23.416 .9218757⁄16 11.112 .4375 15⁄16 23.812 .9375

29⁄64 11.509 .453125 61⁄64 24.209 .95312515⁄32 11.906 .46875 31⁄32 24.606 .9687531⁄64 12.303 .484375 63⁄64 25.003 .9843751⁄2 12.700 .5

218

AREA AND CIRCUMFERENCE OF CIRCLES (INCHES)

Dia. Area Cir. Dia. Area Cir. Dia. Area Cir. Dia. Area Cir.

1⁄8 0.0123 .3926 10 78.54 31.41 30 706.86 94.24 65 3318.3 204.21⁄4 0.0491 .7854 101⁄2 86.59 32.98 31 754.76 97.38 66 3421.2 207.33⁄8 0.1104 1.178 11 95.03 34.55 32 804.24 100.5 67 3525.6 210.41⁄2 0.1963 1.570 111⁄2 103.86 36.12 33 855.30 103.6 68 3631.6 213.65⁄8 0.3067 1.963 12 113.09 37.69 34 907.92 106.8 69 3739.2 216.7

3⁄4 0.4417 2.356 121⁄2 122.71 39.27 35 962.11 109.9 70 3848.4 219.97⁄8 0.6013 2.748 13 132.73 40.84 36 1017.8 113.0 71 3959.2 223.0

1 0.7854 3.141 131⁄2 143.13 42.41 37 1075.2 116.2 72 4071.5 226.1

11⁄8 0.9940 3.534 14 153.93 43.98 38 1134.1 119.3 73 4185.3 229.3

11⁄4 1.227 3.927 141⁄2 165.13 45.55 39 1194.5 122.5 74 4300.8 232.4

13⁄8 1.484 4.319 14 176.71 47.12 40 1256.6 125.6 75 4417.8 235.6

11⁄2 1.767 4.712 151⁄2 188.69 48.69 41 1320.2 128.8 76 4536.4 238.7

15⁄8 2.073 5.105 16 201.06 50.26 42 1385.4 131.9 77 4656.0 241.9

13⁄4 2.405 5.497 161⁄2 213.82 51.83 43 1452.2 135.0 78 4778.3 245.0

17⁄8 2.761 5.890 17 226.98 53.40 44 1520.5 138.2 79 4901.6 248.1

2 3.141 6.283 171⁄2 240.52 54.97 45 1590.4 141.3 80 5026.5 251.3

21⁄4 3.976 7.068 18 254.46 56.46 46 1661.9 144.5 81 5153.0 254.4

21⁄2 4.908 7.854 181⁄2 268.80 58.11 47 1734.9 147.6 82 5281.0 257.6

23⁄4 5.939 8.639 19 283.52 59.69 48 1809.5 150.7 83 5410.6 260.7

3 7.068 9.424 191⁄2 298.64 61.26 49 1885.7 153.9 84 5541.7 263.8

31⁄4 8.295 10.21 20 314.16 62.83 50 1963.5 157.0 85 5674.5 257.0

31⁄2 9.621 10.99 201⁄2 330.06 64.40 51 2042.8 160.2 86 5808.8 270.1

33⁄4 11.044 11.78 21 346.36 65.97 52 2123.7 163.3 87 5944.6 272.3

4 12.566 12.56 211⁄2 363.05 67.54 53 2206.1 166.5 88 6082.1 276.4

41⁄2 15.904 14.13 22 380.13 69.11 54 2290.2 169.6 89 6221.1 279.6

5 19.635 15.70 221⁄2 397.60 70.68 55 2375.8 172.7 90 6361.7 282.7

51⁄2 23.758 17.27 23 415.47 72.25 56 2463.0 175.9 91 6503.8 285.8

6 28.274 18.84 231⁄2 433.73 73.82 57 2551.7 179.0 92 6647.6 289.0

61⁄2 33.183 20.42 24 452.39 75.39 58 2642.0 182.2 93 6792.9 292.1

7 38.484 21.99 241⁄2 471.43 76.96 59 2733.9 185.3 94 6939.7 295.3

71⁄2 44.178 23.56 25 490.87 78.54 60 2827.4 188.4 95 7088.2 298.4

8 50.265 25.13 26 530.93 81.68 61 2922.4 191.6 96 7238.2 301.5

81⁄2 56.745 26.70 27 572.55 84.82 62 3019.0 194.7 97 7389.8 304.7

9 63.617 28.27 28 615.75 87.96 63 3117.2 197.9 98 7542.9 307.8

91⁄2 70.882 29.84 29 660.52 91.10 64 3216.9 201.0 99 7697.7 311.0

219

TRIGONOMETRIC FUNCTIONS

Angle Sin Cos Tan Angle Sin Cos Tan

0 0.000 1.000 0.000 46 0.719 0.695 1.041 0.017 0.999 0.017 47 0.731 0.682 1.072 0.035 0.999 0.035 48 0.743 0.699 1.113 0.052 0.999 0.052 49 0.755 0.656 1.154 0.070 0.998 0.070 50 0.766 0.643 1.19

5 0.087 0.996 0.087 51 0.777 0.629 1.236 0.105 0.995 0.105 52 0.788 0.616 1.287 0.112 0.993 0.123 53 0.799 0.602 1.338 0.139 0.990 0.141 54 0.809 0.588 1.389 0.156 0.988 0.158 55 0.819 0.574 1.4310 0.174 0.985 0.176 56 0.829 0.559 1.48

11 0.191 0.982 0.194 57 0.839 0.545 1.5412 0.208 0.978 0.213 58 0.848 0.530 1.6013 0.225 0.974 0.231 59 0.857 0.515 1.6614 0.242 0.970 0.249 60 0.866 0.500 1.7315 0.259 0.966 0.268 61 0.875 0.485 1.80

16 0.276 0.961 0.287 62 0.883 0.469 1.8817 0.292 0.956 0.306 63 0.891 0.454 1.9618 0.309 0.951 0.325 64 0.898 0.438 2.0519 0.326 0.946 0.344 65 0.906 0.423 2.1420 0.342 0.940 0.364 66 0.914 0.407 2.25

21 0.358 0.934 0.384 67 0.921 0.391 2.3622 0.375 0.927 0.404 68 0.927 0.375 2.4823 0.391 0.921 0.424 69 0.934 0.358 2.6124 0.407 0.914 0.445 70 0.940 0.342 2.7525 0.423 0.906 0.466 71 0.946 0.326 2.90

26 0.438 0.898 0.488 72 0.951 0.309 3.0827 0.454 0.891 0.510 73 0.956 0.292 3.2728 0.469 0.883 0.532 74 0.961 0.276 3.4929 0.485 0.875 0.554 75 0.966 0.259 3.7330 0.500 0.866 0.577 76 0.970 0.242 4.01

31 0.515 0.857 0.601 77 0.974 0.225 4.3332 0.530 0.848 0.625 78 0.978 0.208 4.7033 0.545 0.839 0.649 79 0.982 0.191 5.1434 0.559 0.829 0.675 80 0.985 0.174 5.6735 0.574 0.819 0.700 81 0.988 0.156 6.31

36 0.588 0.809 0.727 82 0.990 0.139 7.1237 0.602 0.799 0.754 83 0.993 0.122 8.1438 0.616 0.788 0.781 84 0.995 0.105 9.5139 0.629 0.777 0.810 85 0.996 0.087 11.4340 0.643 0.766 0.839 86 0.998 0.070 14.30

41 0.656 0.755 0.869 87 0.999 0.035 19.0842 0.669 0.743 0.900 88 0.999 0.035 28.6443 0.682 0.731 0.933 89 0.999 0.017 57.2844 0.695 0.719 0.966 90 1.000 0.000 Infinity45 0.707 0.707 1.000

220

THEORETICAL WEIGHTS OF STEEL PLATES

Wt. per Wt. per Wt. perSize Sq. Ft. Size Sq. Ft. Size Sq. Ft.

(Inches) (Lbs.) (Inches) (Lbs.) (Inches) (Lbs.)

3⁄16 7.65 9/16 22.95 11⁄4 51.001⁄4 10.20 5/8 25.50 13⁄8 56.105⁄16 12.75 3/4 30.60 11⁄2 61.203⁄8 15.30 7/8 35.70 15⁄8 66.307⁄16 17.85 1 40.80 13⁄4 71.401⁄2 20.40 11/8 45.90 2 81.60

Wt. per Wt. per Wt. perSize Sq. Ft. Size Sq. Ft. Size Sq. Ft.

(Inches) (Lbs.) (Inches) (Lbs.) (Inches) (Lbs.)

1 11.25 16 .0598 2.5002 10.625 17 .0538 2.2503 .2391 10.000 18 .0478 2.0004 .2242 9.375 19 .0418 1.7505 .2092 8.750 20 .0359 1.500

6 .1943 8.125 21 .0329 1.3757 .1793 7.500 22 .0299 1.2508 .1644 6.875 23 .0269 1.1259 .1494 6.250 24 .0239 1.00010 .1345 5.625 25 .0209 .875

11 .1196 5.000 26 .0179 .75012 .1046 4.375 27 .0164 .687513 .0897 3.750 28 .0149 .62514 .0747 3.125 29 .0135 .562515 .0673 2.812 30 .0120 .500

STANDARD STEEL SHEET GAUGES & WEIGHTS

NOTE: (1/4" Thick and Heavier Are Called Plates.)

To avoid errors specify decimal part of one inch or mention gaugenumber and the name of the gauge. Orders for a definite gaugeweight or gauge thickness will be subject to standard gauge weightor gauge thickness tolerance, applying equally plus and minus formthe ordered gauge weight or gauge thickness.

U.S. Standard Gauge—Iron and steel sheets. Note: U.S. StandardGauge was established by act of Congress in 1893, in which weightsper square foot were indicated by gauge number. The weight, notthickness, is determining factor when the material is ordered to thisgauge.

221

APPROXIMATE WEIGHTS PER LINEAL FOOTIN POUNDS OF STANDARD STEEL BARS

Dia. Dia.In. Rd. Hex. Sq. In. Rd. Hex. Sq.

1⁄16 .101 .012 .013 27⁄32 .190 2.10 2.423⁄32 .023 .026 .030 7⁄8 2.04 2.25 2.601⁄8 .042 .046 .053 29⁄32 2.19 2.42 2.795⁄32 .065 .072 .083 15⁄16 2.35 2.59 2.993⁄16 .094 .104 .120 31⁄32 2.51 2.7 3.197⁄32 .128 .141 .163 1 2.67 2.95 3.401⁄4 .167 .184 .212 11⁄16 3.01 3.32 3.849⁄32 .211 .233 .269 11⁄8 3.38 3.37 4.305⁄16 .261 .288 .332 13⁄16 3.77 4.15 4.8011⁄32 .316 .348 .402 11⁄4 4.17 4.60 5.313⁄8 .376 .414 .478 15⁄16 4.60 5.07 5.86

13⁄32 .441 .486 .561 13⁄8 5.05 5.57 6.437⁄16 .511 .564 .651 17⁄16 5.52 6.09 7.0315⁄32 .587 .647 .747 11⁄2 6.01 6.63 7.651⁄2 .667 .736 .850 15⁄8 7.05 7.78 8.98

17⁄32 .754 .831 .960 13⁄4 8.18 9.02 10.419⁄16 .845 .932 1.08 17⁄8 9.39 10.36 11.9519⁄32 .941 1.03 1.20 2 10.68 11.78 13.605⁄8 1.04 1.15 1.33 21⁄8 12.06 13.30 15.35

21⁄32 1.15 1.27 1.46 21⁄4 13.52 14.91 17.2111⁄16 1.26 1.39 1.61 23⁄8 15.06 16.61 19.1823⁄32 1.38 1.52 1.76 21⁄2 16.69 18.40 21.253⁄4 1.50 1.66 1.91 23⁄4 20.20 22.27 25.71

25⁄32 1.63 1.80 2.08 3 24.03 26.50 30.6013⁄16 1.76 1.94 2.24

WEIGHTS OF FLAT BARS AND PLATESTo find weight per foot of flat steel, multiply width in inches byfigure listed below:

APPROXIMATE WEIGHT OF VARIOUS METALSTo find weight of various metals, multiply contents in cubic inchesby the number shown; result will be approximate weight in pounds.

Thickness Thickness Thickness1⁄16". . . . . . . . . . . . . .2125 7⁄8" . . . . . . . . . . . . . 2.975 13⁄4" . . . . . . . . . . . 5.95011⁄8" . . . . . . . . . . . . .4250 15⁄16" . . . . . . . . . . . . 3.188 113⁄16" . . . . . . . . . . 6.1633⁄16". . . . . . . . . . . . . .6375 1" . . . . . . . . . . . . . 3.400 17⁄8" . . . . . . . . . . . 6.3751⁄4" . . . . . . . . . . . . . .8500 11⁄16" . . . . . . . . . . . . 3.613 115⁄16" . . . . . . . . . . 6.5885⁄16". . . . . . . . . . . . 1.0600 11⁄8" . . . . . . . . . . . . 3.825 2" . . . . . . . . . . . . . 6.8003⁄8" . . . . . . . . . . . . 1.2750 13⁄16" . . . . . . . . . . . . 4.038 21⁄8" . . . . . . . . . . . 7.2257⁄16". . . . . . . . . . . . 1.4880 11⁄4" . . . . . . . . . . . . 4.250 21⁄4" . . . . . . . . . . . 7.6501⁄2" . . . . . . . . . . . . 1.7000 115⁄16". . . . . . . . . . . 4.463 23⁄8" . . . . . . . . . . . 8.0759⁄16". . . . . . . . . . . . 1.9130 13⁄8" . . . . . . . . . . . . 4.675 21⁄2" . . . . . . . . . . . 8.5005⁄8" . . . . . . . . . . . . 2.1250 17⁄16" . . . . . . . . . . . 4.888 25⁄8" . . . . . . . . . . . 8.92511⁄16" . . . . . . . . . . . 2.3380 11⁄2" . . . . . . . . . . . . 5.100 23⁄4" . . . . . . . . . . . 9.3503⁄4" . . . . . . . . . . . . 2.5500 19⁄16" . . . . . . . . . . . 5.313 27⁄8" . . . . . . . . . . . 9.77513⁄16". . . . . . . . . . . . . . . . . . . . . . . 2.7630 15⁄8" . . . . . . . . . . . . 5.525 3" . . . . . . . . . . . . 10.200

111⁄16" . . . . . . . . . . . 5.738

Iron. . . . . . . . . . . . . . . . . . . .27777Steel . . . . . . . . . . . . . . . . . . .28332Copper . . . . . . . . . . . . . . . . .32118Brass . . . . . . . . . . . . . . . . . .31120

Lead . . . . . . . . . . . . . . . . . . .41015Zinc . . . . . . . . . . . . . . . . . . .25318Tin . . . . . . . . . . . . . . . . . . . .26562Aluminum. . . . . . . . . . . . . . .09375

222

STEEL WIRE GAUGE DATABrown & Steel WireSharpe or Gauge

Thickness *Wt. per American (WashburnGa. No. Inches Sq. Ft. Wire & Moren)

3 .259 10.567 .2294 .24374 .238 9.710 .2043 .22535 .220 8.976 .1819 .2070

6 .203 8.282 .1620 .19207 .180 7.344 .1443 .17708 .165 6.732 .1285 .16209 .148 6.038 .1144 .148310 .134 5.467 .1019 .1350

11 .120 4.896 .0907 .120512 .109 4.447 .0808 .105513 .095 3.876 .0720 .091514 .083 3.386 .0641 .080015 .072 2.938 .0571 .0720

16 .065 2.652 .0508 .062517 .058 2.366 .0453 .054018 .049 1.999 .0403 .047519 .042 1.714 .0359 .041020 .035 1.428 .0320 .0348

21 .032 1.306 .0285 .031722 .028 1.142 .0253 .028623 .025 1.020 .0226 .025824 .022 .898 .0201 .023025 .020 .816 .0179 .0204

26 .018 .734 .0159 .018127 .016 .653 .0142 .017328 .014 .571 .0126 .016229 .013 .530 .0113 .015030 .012 .490 .0100 .0140

NOTE: Birmingham or Stubs Gauge—Cold rolled strip, round edge flat wire,cold roll spring steel, seamless steel and stainless tubing and boilertubes.

*B.W. Gauge weights per sq. ft. are theoretical and based on steelweight of 40.8 lbs. per sq. ft. of 1" thickness; weight of hot rolledstrip is predicted by using this factor.

Steel Wire Gauge—(Washburn & Moen Gauge)—Round steel wire inblack annealed, bright basic, galvanized, tinned and copper coated.

Birmingham Wire Gaugeor Stubs Gauge

223

ROCKWELL-BRINELL CONVERSION TABLEBrinell Rockwell Brinell Rockwell

Numbers C Scale Numbers C Scale10 mm Ball Brale Penetrator 10 mm Ball Brale Penetrator

3000 kg Load 150 kg Load 3000 kg Load 150 kg Load

690 65 393 42673 64 382 41658 63 372 40645 62 362 39628 61 352 38614 60 342 37600 59 333 36587 58573 57 322 35560 56 313 34

305 33547 55 296 32534 54 290 31522 53 283 30509 52 276 29496 51 272 28484 50 265 27472 49 260 26460 48448 47 255 25437 46 248 24

245 23426 45 240 22415 44 235 21404 43 230 20

Coarse Fine Coarse FineSize NC NF Size NC NF

0 80 9⁄16 12 181 64 72 5⁄8 11 182 56 64 3⁄4 10 163 48 56 7⁄8 9 144 40 48 1 8 145 40 44 11⁄8 7 126 32 40 11⁄4 78 32 36 13⁄8 6

10 24 32 11⁄2 6 1212 24 28 13⁄4 51⁄4 20 28 2 41⁄2

5⁄16 18 24 21⁄4 41⁄23⁄8 16 24 21⁄2 47⁄16 14 20 23⁄4 41⁄2 13 20 3 4

Over 3

AMERICAN STANDARD COARSEAND FINE THREAD SERIES

Threads per inch Threads per inch

224

SPEED RATIOSSpeed ratios and groups from which speed change selection can be made.

Ratio of transmissionRevolutions per minute of faster shaftRevolutions per minute of slower shaft

=

Number of Teeth in Driver Gear & Sprocket17 19 21 23 25 27 30 33

19 1.12 1.00 0.91 0.83 0.76 0.70 0.64 0.5821 1.23 1.10 1.00 0.91 0.84 0.78 0.70 0.6523 1.35 1.21 1.10 1.00 0.92 0.85 0.78 0.7025 1.47 1.32 1.19 1.09 1.00 0.93 0.83 0.7627 1.59 1.42 1.28 1.17 1.08 1.00 0.90 0.8230 1.77 1.58 1.43 1.30 1.20 1.11 1.00 0.9133 1.94 1.74 1.57 1.43 1.32 1.22 1.19 1.0036 2.12 1.89 1.71 1.56 1.44 1.33 1.20 1.0940 2.35 2.10 1.90 1.74 1.60 1.48 1.33 1.2145 2.65 2.37 2.14 1.96 1.80 1.67 1.50 1.3650 2.94 2.63 2.38 2.18 2.00 1.85 1.67 1.5255 3.24 2.89 2.62 2.39 2.20 2.04 1.83 1.6760 3.53 3.16 2.86 2.61 2.40 2.22 2.00 1.8268 4.00 3.58 3.24 2.96 2.72 2.52 2.2775 4.41 3.95 3.57 3.26 3.00 2.7884 4.94 4.42 4.00 3.65 3.3690 5.30 4.74 4.28 3.91102 6.00 5.37 4.86

Number of Teeth in Driver Gear & Sprocket36 40 45 50 55 60 68 75

19 0.53 0.48 0.42 0.38 0.35 0.32 0.28 0.2521 0.58 0.53 0.47 0.42 0.38 0.35 0.31 0.2823 0.64 0.58 0.51 0.46 0.42 0.38 0.34 0.3125 0.70 0.63 0.56 0.50 0.46 0.42 0.37 0.3327 0.75 0.68 0.60 0.54 0.49 0.45 0.40 0.3630 0.83 0.75 0.67 0.60 0.55 0.50 0.4433 0.92 0.83 0.73 0.66 0.60 0.5536 1.00 0.90 0.80 0.72 0.6540 1.11 1.00 0.89 0.8045 1.25 1.13 1.0050 1.30 1.2555 1.53

GENERAL INFORMATION ON CHAINSThe chain drive has three elements; the driver sprocket, the drivensprocket, and the endless chain which transmits power form the firstto the second. The distance from center to center of adjacent chainpins is the chain pitch and also the sprocket pitch.

Chain speed, except for high speed RC and silent chains, should notexceed 500 ft. per min. Working load should be held under 1⁄6 theultimate strength for speeds up to 200 f.p.m., 1/10 where speed isbetween 200 and 300 f.p.m., and less if speed exceeds 300 f.p.m.

Chain speed, f.p.m. No. of teeth in sprocket x chain pitch (in.) x r.p.m.12

=

H.P. of drive Chain speed in f.p.m. x pull in pounds33,000

=

Nu

mb

er o

f Te

eth

in D

rive

n G

ear

& S

pro

cket

225

CONVERSION OF THERMOMETER SCALE

°C. °F. °C. °F. °C. °F. °C. °F. °C. °F.-80 -112. 1 33.8 31 87.8 61 141.8 91 195.8-70 -94. 2 35.6 32 89.6 62 143.6 92 197.6-60 -76. 3 37.4 33 91.4 63 145.4 93 199.4-50 -58.0 4 39.2 34 93.2 64 147.2 94 201.2-45 -49.1 5 41.0 35 95.0 65 149.0 95 203.0-40 -40.0 6 42.8 36 96.8 66 150.8 96 204.8-35 -31.0 7 44.6 37 98.6 67 152.6 97 206.6-30 -22.0 8 46.4 38 100.4 68 154.4 98 208.4-25 -13.0 9 48.2 39 102.2 69 156.2 99 210.2-20 -4.0 10 50.0 40 104.0 70 158.0 100 212.0-19 -2.2 11 51.8 41 105.8 71 159.8 105 221.-18 -.4 12 53.6 42 107.6 72 161.6 110 230.-17 1.4 13 55.4 43 109.4 73 163.4 115 239.-16 3.2 14 57.2 44 111.2 74 165.2 120 248.-15 5.0 15 59.0 45 113.0 75 167.0 130 266.-14 6.8 16 60.8 46 114.8 76 168.8 140 284.-13 8.6 17 62.6 47 116.0 77 170.6 150 302.-12 10.4 18 64.4 48 118.4 78 172.4 160 320.-11 12.2 19 66.2 49 120.2 79 174.2 170 338.-10 14.0 20 68.0 50 122.0 80 176.0 180 356.-9 15.8 21 69.8 51 123.8 81 177.8 190 374.-8 17.6 22 71.6 52 125.6 82 179.6 200 392.-7 19.4 23 73.4 53 127.4 83 181.4 250 482.-6 21.2 24 75.2 54 129.2 84 183.2 300 572.-5 23.0 25 77.0 55 131.0 85 185.0 350 662.-4 24.8 26 78.8 56 132.8 86 186.8 400 752.-3 26.6 27 80.6 57 134.6 87 188.6 500 932.-2 28.4 28 82.4 58 136.4 88 190.4 600 1112.-1 30.2 29 84.2 59 138.2 89 192.2 700 1292.0 32.0 30 86.0 60 140.0 90 194.0 800 1472.

900 1652.1000 1832.

MISCELLANEOUS USEFUL INFORMATIONTo 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 ofwater when pressure in pounds per square inch is known, multiplypressure in pounds by 2.309 (2.309 Feet Water exerts pressure onone pound per square inch.)

Centigrade — Fahrenheit°C. = 5/9 (°F.—32) °F. = 9/5 °C. = 32

226

APPROX. SAFE LOAD FOR CHAINS AND WIRE ROPESUNDER DIFFERENT LOADING CONDITIONS

Single Leg Double LegAlloyChainSize

Inch mm Lbs. kg Lbs. kg Lbs. kg Lbs. kg1⁄4 6.35 3,250 1474 5,660 2563 4,600 2086 3,250 14743⁄8 9.52 6,600 2994 11,400 5171 9,300 4218 6,600 29941⁄2 12.7 11,250 5103 19,500 8845 15,900 7212 11,250 51035⁄8 15.9 16,500 7484 28,600 12973 23,300 10559 16,500 74843⁄4 19.0 23,000 10433 39,800 18053 32,500 14742 23,000 104337⁄8 22.2 28,750 13041 49,800 22589 40,700 18461 28,750 13041

1 25.4 38,750 17577 67,100 30436 54,800 24857 38,750 17577

11⁄4 31.7 57,500 26082 99,600 45178 81,300 36878 57,500 26082

Alloy Sling Chain ASTM A-391 Approx. Working Load Limits

The above Working Load Limits are based upon using chain having aworking load equal to that shown in column for single leg.

Courtesy of The Crosby Group

*Ton = 2,000 lbs. Courtesy Macwhyte Company

1 Sling Vertical 2 Legs 60° 2 Legs 45° 2 Legs 30°Single-PartRope Body

Size

Inch mm Tons* mt Tons* mt Tons* mt Tons* mt1⁄2 12.7 1.8 1.6 3.2 2.9 2.6 2.4 1.8 1.69⁄16 14.3 2.3 2.1 4.0 3.6 3.2 2.9 2.3 2.15⁄8 15.9 2.8 2.5 4.8 4.4 4.0 3.6 2.8 2.53⁄4 19.0 3.9 3.5 6.8 6.2 5.5 5.0 3.9 3.57⁄8 22.2 5.1 4.6 8.9 8.1 7.3 6.6 5.1 4.6

1 25.4 6.7 6.1 11.0 10.0 9.4 8.5 6.7 6.1

11⁄8 28.6 8.4 7.6 14.0 12.7 12.0 10.9 8.4 7.6

11⁄4 31.7 10.0 9.1 18.0 16.3 15.0 13.6 10.0 9.1

13⁄8 34.9 12.0 10.9 21.0 19.0 17.0 15.4 12.0 10.9

11⁄2 38.1 15.0 13.6 25.0 22.7 21.0 19.0 15.0 13.6

15⁄8 41.3 17.0 15.4 30.0 27.2 24.0 21.8 17.0 15.4

13⁄4 44.4 20.0 18.1 34.0 30.8 28.0 25.4 20.0 18.1

17⁄8 47.6 22.0 20.0 39.0 35.4 34.0 30.8 22.0 20.0

2 50.8 26.0 23.6 44.0 40.0 36.0 32.6 26.0 23.6

WIRE ROPE

RATED CAPACITY (Approx.)

227

AVERAGE SAFE CONCENTRATED LOADS ONWOODEN BEAMS—AVERAGE CONDITIONS

Concentrated Load = 1⁄2 of uniformly distributed load.

Span Load

Width Depth

Ft. meters In. mm In. mm Lbs. kg

4 1.219 6 152 6 152 2,100 952.6

8 203 8 203 4,970 2254

8 203 10 254 7,765 3522

6 1.829 6 152 6 152 1,398 634.1

6 152 8 203 2,490 1129

8 203 8 203 3,320 1506

8 203 10 254 5,184 2351

10 254 10 254 6,480 2939

10 254 12 305 9,330 4232

12 305 12 305 11,197 5097

8 2.438 6 152 6 152 1,050 476.3

6 152 8 203 1,866 846.4

8 203 8 203 2,488 1128

8 203 10 254 3,888 1763

10 254 10 254 4,860 2204

10 254 12 305 7,000 3175

12 305 12 305 8,400 3810

BeamDimension

Unde

r ide

al c

ondi

tions

the

load

can

be

incr

ease

d 1 ⁄3

Lbs.PerSq.Yd. 1 2 3 4 5 6 7 8 9 10 20 30 40 50 601 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 17.62 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 35.23 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 52.84 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 70.45 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 88.06 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 88.0 105.67 2.1 4.1 6.2 8.2 10.3 12.3 14.4 16.4 18.5 20.5 41.1 61.5 82.1 102.7 123.28 2.3 4.7 7.0 9.4 11.7 14.1 16.4 18.8 21.1 23.5 46.9 70.4 93.9 117.3 140.89 2.6 5.3 7.9 10.6 13.2 15.8 18.5 21.1 23.8 26.4 52.8 79.2 105.6 132.0 158.410 2.9 5.9 8.8 11.7 14.7 17.6 20.5 23.5 26.4 29.3 58.7 88.0 117.3 146.7 176.020 5.9 11.7 17.6 23.5 29.3 35.2 41.1 46.9 52.8 58.7 117.3 176.0 234.7 293.3 352.030 8.8 17.6 26.4 35.2 44.0 52.8 61.6 70.4 79.2 88.0 176.0 264.0 352.0 440.0 527.940 11.7 23.5 35.2 46.9 58.7 70.4 82.1 93.9 105.6 117.3 234.7 352.0 469.3 586.7 704.050 14.7 29.3 44.0 58.7 73.3 88.0 102.7 117.3 132.0 146.7 293.3 440.0 586.7 733.3 880.060 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 1056.070 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 1232.080 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 1408.090 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 1584.0100 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 1760.0200 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 3520.0300 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 5280.0400 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 7040.0500 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 8800.0600 176.0 352.0 528.0 704.0 880.0 1056.0 1232.0 1408.0 1584.0 1760.0 3520.0 5280.0 7040.0 8800.0 10560.0700 205.3 410.7 616.0 821.3 1026.7 1232.0 1437.3 1642.7 1848.0 2053.3 4106.7 6160.0 8213.3 10266.7 12320.0800 234.7 469.3 704.0 938.7 1173.3 1408.0 1642.7 1877.3 2112.0 2346.7 4693.3 7040.0 9386.7 11733.3 14080.0900 264.0 528.0 792.0 1056.0 1320.0 1584.0 1848.0 2112.0 2376.0 2640.0 5280.0 7920.0 10560.0 13200.0 15840.01000 293.3 586.7 880.0 1173.3 1466.7 1760.0 2053.3 2346.7 2640.0 2933.3 5866.7 8800.0 11733.3 14666.7 17600.0

228 TONS OF MATERIAL REQUIRED PER MILE FOR VARIOUS WIDTHS AND POUNDS PER SQUARE YARD

NOTE: Formula used forcalculation is as follows:

w = = 0.2933 RWWhere w = Weight of material in tons per mile

R = Rate of application in lbs. per sq. yd.W = Width of application in feet

Data FromThe Asphalt Institute

W__

3( ) 5280

_____

3( ) R

____

2000( )

WIDTH - FEET

229

APPROXIMATE CUBIC YARDS OF AGGREGATE REQUIRED FOR ONE MILE OF ROAD ATVARIOUS WIDTHS AND LOOSE DEPTHS—(See Note)

NOTE: 16.30 cubic yards—1" deep, 1' wide and 1 mile long. To obtain the amount of material required for depth after compaction, increase the above figures 15% to30% depending on the type and gradation of material.

Width of Sq. Yds.Road Per(Ft.) Mile 1 2 3 4 5 6 7 8 9 10

1 587 16 33 49 65 81 98 114 130 147 1638 4693 130 261 391 521 652 782 913 1043 1173 13049 5280 147 293 440 587 733 880 1027 1173 1320 146710 5867 163 326 489 652 815 978 1141 1304 1467 163012 7040 196 391 587 782 978 1173 1369 1565 1760 195614 8213 228 456 685 912 1141 1369 1597 1825 2054 228215 8800 244 489 733 977 1222 1467 1711 1955 2200 244516 9387 261 521 782 1042 1304 1564 1827 2086 2347 260818 10560 293 587 880 1173 1467 1760 2053 2347 2641 293320 11733 326 652 978 1304 1630 1956 2281 2607 2933 325922 12907 358 717 1076 1434 1793 2152 2510 2868 3228 358624 14080 391 782 1173 1564 1956 2347 2738 3128 3521 391226 15253 424 847 1271 1694 2119 2543 2966 3388 3815 423828 16427 456 913 1369 1824 2282 2738 3194 3684 4108 456430 17600 489 879 1467 1956 2444 2933 3422 3911 4440 488940 23467 652 1304 1956 2607 3259 3911 4563 5215 5867 6519

LOOSE DEPTH (Inches)

Density(Lbs. perCu. Yd) 1 2 3 4 5 6 7 8 9 10 12

1500 41.7 83.3 125.0 166.7 208.3 250.0 291.7 333.3 375.0 416.6 500.01600 44.4 88.9 133.3 177.8 222.2 266.7 311.0 355.5 400.0 444.4 533.31700 47.2 94.5 141.6 188.9 236.1 283.3 330.4 377.8 425.0 472.2 566.71800 50.0 100.0 150.0 200.0 250.0 300.0 350.0 400.0 450.0 500.0 600.01900 52.8 105.5 158.3 211.1 263.9 316.7 369.4 422.2 475.0 527.8 633.32000 55.6 111.1 166.7 222.2 277.8 333.3 388.9 444.4 500.0 555.6 666.72100 58.3 116.7 175.0 233.3 291.7 350.0 408.3 466.7 525.5 583.4 733.32200 61.1 122.2 183.3 244.4 305.6 366.7 427.8 488.9 550.0 611.1 733.32300 63.9 127.8 191.7 255.5 319.5 383.3 447.2 511.1 575.0 638.9 766.62400 66.7 133.3 200.0 266.7 333.3 400.0 466.7 533.3 600.0 666.7 800.02500 69.4 138.9 208.3 277.8 347.2 416.7 486.1 555.5 625.0 694.4 833.32600 72.2 144.4 216.7 288.9 361.1 433.3 505.6 577.8 650.0 722.2 866.72700 75.0 150.0 225.0 300.0 375.0 450.0 525.0 600.0 675.0 750.0 900.02800 77.8 155.5 233.3 311.1 388.9 466.7 544.4 622.2 700.0 777.8 933.32900 80.6 161.1 241.7 322.2 402.8 483.3 563.9 644.4 725.0 805.6 966.73000 83.3 166.7 250.0 333.3 416.7 500.0 563.3 666.7 750.0 833.3 1000.03100 86.1 172.2 258.3 344.4 430.6 516.7 602.8 688.9 775.0 861.2 1033.33200 88.9 177.8 266.7 355.5 444.5 533.3 622.2 711.1 800.0 888.9 1066.73300 91.7 183.3 275.0 366.7 458.3 550.0 641.7 733.3 825.0 944.4 1133.33400 94.4 188.9 283.3 377.8 472.2 566.7 661.1 755.5 850.0 944.4 1133.3

3500 97.2 194.4 291.7 388.9 486.1 583.3 680.6 777.8 875.0 972.2 1166.73600 100.0 200.0 300.0 400.0 500.0 600.0 700.0 800.0 900.0 1000.0 1200.03700 102.8 205.5 308.3 411.1 513.9 626.7 719.4 822.2 925.0 1027.8 1233.3

230 APPROXIMATE WEIGHT IN POUNDS PER SQUARE YARD OF AGGREGATES OF VARYING DENSITIES AT VARIOUS DEPTHSDEPTH (Inches)

231

Area(Square

Feet) 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.010 .03 .05 .06 .08 .09 .11 .13 .14 .15 .17 .1920 .06 .09 .12 .16 .19 ,22 .25 .28 .31 .34 .3730 .09 .14 .19 .23 .28 .33 .37 .42 .46 .41 .56

40 .12 .19 .25 .31 .37 .43 .50 .56 .62 .68 .7450 .15 .23 .31 .39 .46 .54 .62 .70 .77 .85 .9360 .19 .28 .37 .46 .56 .65 .74 .83 .93 1.02 1.11

70 .22 .32 .43 .54 .65 .76 .87 .97 1.08 1.19 1.3080 .25 .37 .49 .62 .74 .87 1.00 1.11 1.24 1.36 1.6790 .28 .42 .56 .70 .84 .97 1.11 1.25 1.39 1.53 1.67

100 .31 .46 .62 .78 .93 1.08 1.24 1.39 1.55 1.70 1.85200 .62 .93 1.23 1.54 1.85 2.16 2.47 2.78 3.09 3.40 3.70300 .93 1.39 1.85 2.32 2.78 3.24 3.70 4.17 4.63 5.10 5.56

400 1.23 1.83 2.47 3.10 3.70 4.32 4.94 5.56 6.17 6.79 7.41500 1.54 2.32 3.09 3.86 4.63 5.40 6.17 7.00 7.72 8.49 9.26600 1.85 2.78 3.70 4.63 5.56 6.48 7.41 8.33 9.26 10.19 11.11

700 2.16 3.24 4.32 5.40 6.48 7.56 8.64 9.72 10.80 11.88 12.96800 2.47 3.70 4.94 6.20 7.41 8.64 9.88 11.11 12.35 13.58 14.82900 2.78 4.17 5.56 6.95 8.33 9.72 11.11 12.50 13.89 15.28 16.671000 3.09 4.63 6.17 7.72 9.26 10.80 12.35 13.89 15.43 16.98 18.52

APPROXIMATE CUBIC YARDS OF CONCRETE IN SLABS OF VARIOUS AREAS AND THICKNESS

THICKNESS OF SLABS (Inches)

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.

232

DEFINITIONS AND TERMSAdmixtures—Substances, not normally a part of pavingmaterials or mixtures, added to them to modify their prop-erties.

Agglomeration—Gathering into a ball or mass.

Aggregates—In the case of materials for construction,essentially inert materials which when bound together intoa conglomerated mass by a matrix form asphalt, concrete,mortar or plaster; crushed rock or gravel screened to sizefor use on road surfaces.

Ballast—Broken stone or gravel used in stabilizing a roadbed or making concrete.

Bank Gravel—Gravel found in natural deposits, usuallymore or less intermixed with fine material, such as sand orclay, or combinations thereof; gravelly clay, gravelly sandclayey gravel and sandy gravel, indicate the varying pro-portions of the materials in the mixture.

Base—Foundation for pavement.

Beneficiation—Improvement of the chemical or physicalproperties of a material or intermediate product by theremoval of undesirable components or impurities.

Binder Course—The course, in sheet asphalt and bitu-minous concrete pavements, placed between base andsurface courses.

Binder Soil—Material consisting primarily of fine soil par-ticles (fine sand, silt, true clay and colloids); good bindingproperties; commonly referred to as clay binder.

Bleeding—Upward migration of bituminous materialresulting in film of bitumen on surface.

Blow-up—Localized buckling or shattering of rigid pave-ment caused by excessive longitudinal pressure.

Bog—Wet spongy ground sometimes filled with decayedvegetable matter.

Boulders—Detrital material greater than about 8" indiameter.

Construction Joint—Vertical or notched plane of sepa-ration in pavement.

233

DEFINITIONS AND TERMS (Continued)

Contraction Joint—Joint of either full depth or weakenedplane type designed to establish position of any crackcaused by contraction while providing no space for expan-sion of pavement beyond original length.

Corrugations—Regular transverse undulation in surfaceof pavement consisting of alternate valleys and crests.

Cracks—Approximately vertical cleavage due to naturalcauses or traffic action.

Crazing—Pattern cracking extending only through sur-face layer, a result of more drying shrinkage in surfacethan interior of plastic concrete.

“D” Lines—Disintegration characterized by successiveformation of series of fine cracks at rather close intervalsparalleling edges, joints and cracks, and usually curvingacross slab corners. Initial cracks forming very close toslab edge and additional cracks progressively developing,ordinarily filled with calcareous deposit.

Dense and Open Graded Aggregates—Dense appliesto graded mineral aggregate containing sufficient dust ormineral filler to reduce all void spaces in compactedaggregate to exceedingly small diameters approximatingsize of voids in filler itself, may be either coarse or finegraded; open applies to graded mineral aggregate con-taining no mineral filler or so little that void spaces incompacted aggregate are relatively large.

Dewater—To remove water by pumping, drainage orevaporation or a dewatering screw.

Disintegration—Deterioration into small fragments fromany cause.

Distortion—Any deviation of pavement surface from orig-inal shape.

Expansion Joint—Joint permitting pavement to expandin length.

Faulting—Differential vertical displacement of slabs adja-cent to joint or crack.

Flume—An open conduit of wood, concrete or metal.

Gradation—Sieve analysis of aggregates, a general termto describe the aggregate composition of a mix.

234


Gradation Aggregates—Percentages of aggregate inquestion which fall into specified size limits. Purpose ofgrading aggregates is to have balanced gradation ofaggregate so that voids between sizes are progressivelyfilled with smaller particles until voids are negligible.Resulting mix reaches highest mechanical stability with-out binder.

Granites—Crystalline, even-grained rocks consistingessentially of feldspar and quartz with smaller amounts ofmica and other ferro-magnesian minerals.

Gravel—Granular, pebbly material (usually coarser than1/4" in diameter) resulting from natural disintegration ofrock; usually found intermixed with fine sands and clay;can be identified as bank, river or pea gravel; roundedcharacter of some imparted by stream action.

Gravity—The force that tends to pull bodies towards thecenter of mass, to give bodies weight.

Grit—A coarse sand formed mostly of angular quartzgrains.

Gumbo—Soil of finely divided clays of varying capillarity.

“Hollows”—Deficiencies in certain fractions of a pitrungravel.

Igneous—Natural rock composed of solidified moltenmaterial.

Lime Rock—Natural material essentially calcium carbon-ate with varying percentages of silica; hardens uponexposure to elements; some varieties provide excellentroad material.

Limestone—Natural rock of sedimentary origin com-posed principally of calcium carbonate or calcium andmagnesium carbonates in either its original chemical orfragmental, or recrystallized form.

Loam—Soil which breaks up easily, usually consisting ofsand, clay, and organic material.

Loess—An unstratified deposit of yellow-brown loam.

Manufactured Sand—Not natural occurring sand, -3⁄8"material made by crushing +3⁄8" material.

Mesh—The number of openings per lineal inch in wirescreen.

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Metamorphic Rock—Pre-existing rock altered to such anextent as to be classed separately. One of the three basicrock formations, including igneous and sedimentary.

Micron—A unit of length; one thousandth of a millimeter.

Mineral Dust or Filler—Very finely divided mineral prod-uct, great bulk of which will pass No. 200 sieve.Pulverized limestone is most commonly manufacturedfiller; other stone dust, silica, hydrated lime and certainnatural deposits of finely divided mineral matter are alsoused.

Muck—Moist or wet decaying vegetable matter or peat.

Natural Cement—Product obtained by finely pulverizingcalcined argillaceous limestone, to which not to exceed 5percent of nondeleterious materials may be added subse-quent to calcination. Temperature of calcination shall beno higher than necessary to drive off carbonic acid gas.

Ore—Any material containing valuable metallic matterwhich is mined or worked.

Outcropping—A stratum of rock or other material whichbreaks surface of ground.

Overburden—Soil mantle, waste, or similar matter founddirectly above deposit of rock or sand-gravel.

Paving Aggregate—Vary greatly as to grade, quality,type, and composition; general types suitable for bitumi-nous construction can be classified as: Crushed Stone,Gravel, Sand, Slag, Shell, Mineral Dust.

Pebbles—Rock fragments of small or moderate sizewhich have been more or less rounded by erosionalprocesses.

Pitrun—Natural gravel deposits; may contain some sand,clay or silt.

Portland Cement—Product obtained by pulverizingclinker consisting essentially of hydraulic calcium silicatesto which no additions have been made subsequent to cal-cination other than water or untreated calcium sulfate,except that additions not to exceed 1 percent of othermaterials may be interground with clinker at option ofmanufacturer, provided such materials have been shownto be not harmful.

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Riprap—Riprap as used for facing dams, canals, andwaterways is normally a coarse, grade material. Typicalgeneral specifications would call for a minimum 160 lb./ft3

(2563 kg/m3) stone, free of cracks and seams with nosand, clay, dirt, etc.

Sand—Standard classification of soil or granular materialpassing the 3⁄8" (9.52mm) sieve and almost entirely pass-ing the No. 4 (4.76mm) sieve and predominantly retainedon the No. 200 (74 micron) sieve.

Sand Clay (Road Surface)—Surface of sand and claymixture in which the two materials have been blended sotheir opposite qualities tend to maintain a condition of sta-bility under varying moisture content.

Sand, Manufactured—Not natural occurring sand, -3⁄8"material made by crushing +3⁄8" material.

Sandstone—Essentially rounded grains of quartz, with orwithout interstitial cementing materials, with the largergrains tending to be more perfectly rounded than thesmaller ones. The fracture takes place usually in thecement leaving the grains outstanding.

Scalp Rock—Rock passed over a screen and rejected—waste rock.

Screenings—Broken rock, including dust, or size that willpass through 1/2" to 3/4" screen, depending upon char-acter of stone.

Sedimentary—Rocks formed by the deposit of sediment.

Settling Rock—An enlargement to permit the settlementof debris carried in suspension, usually provided withmeans of ejecting the material collected.

Shale—Material composed essentially of silica and alu-mina with a more or less thinly laminated structureimparted by natural stratification of extremely fine sedi-ments together with pressure.

Shell Aggregate—Applies to oyster, clam shells, etc.,used for road surfacing material; shells are crushed tosize but generally must be blended with other fine sandsto produce specification gradation.

Sieve—Test screens with square openings.

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Slag—By-product of blast furnace; usually makes goodpaving material, can be crushed into most any gradation;most are quite porous.

Slates—Rocks, normally clayey in composition, in whichpressure has produced very perfect cleavage; readily splitinto thin, smooth, tough plates.

Slope Angle—The angle with the horizontal at which aparticular material will stand indefinintely without move-ment.

Specific Gravity—The ratio of the mass of a unit volumeof a material at a stated temperature to the mass of thesame volume of a gas-free distilled water at the sametemperature.

Stone—Any natural rock deposit or formation of igneous.sedimentary and/or metamorphic origin, either in originalor altered form.

Stone-Sand—Refers to product (usually less than 1/2" indiameter) produced by crushing of rock; usually highlyprocessed, should not be confused with screenings.

Stratum—A sheet-like mass of sedimentary rock or earthof one kind, usually in layers between bed of other kinds.

Sub-Grade—Native foundation on which is placed roadmaterial or artificial foundation, in case latter is provided.

Sub-Soil—Bed or earth immediately beneath surface soil.

Tailings—Stones which, after going through crusher, donot pass through the largest openings on the screen.

Top-Soil (Road Surface)—A variety of surfacing usedprincipally in southeastern states, being stripping of cer-tain top-soils containing natural sand-clay mixture. Whenplaced on road surface, wetted and puddled under traffic,it develops considerable stability.

Trap—Includes dark-colored, fine-grained, dense igneousrocks composed of ferro-magnesian minerals, basicfeldspars, and little or no quartz; ordinary commercial vari-ety is basalt, diabase, or gabbro.

Viscosity—The measure of the ability of a liquid or solidto resist flow. A liquid with high viscosity will resist flowmore readily than a liquid with low viscosity.

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Voids—Spaces between grains of sand, gravel or soil thatare occupied by water or air or both.

Weir—A structure for diverting or measuring the flow ofwater.

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NOTES:

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NOTES:

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