7 Steps in the Aggregate Manufacturing Process

aggregate material

Aggregate is an important raw material in the infrastructure construction industry. Aggregate is divided into fine aggregate (commonly known as sand, with a particle size between 0.15-4.75mm) and coarse aggregate (commonly known as stone, with a particle size between 4.75-9.0mm).

The aggregate material is loose and granular in shape and is the basic raw material for producing concrete. It not only plays the role of skeleton and filling in concrete, but also reduces concrete shrinkage, inhibits crack expansion, reduces hydration heat, and increases wear resistance. Now that we understand what aggregate is, let us find out how is aggregate produced?

What Is the Aggregate Manufacturing Process?

The aggregate production process mainly concludes 7 steps.

Mining Process

First, we need to mine the raw materials that can be made into aggregates. The methods required for mining include blasting operations, drilling operations, manual digging pile operations and dewatering operations. In actual production, decide which operating method to use based on the hardness of the raw materials. If the raw rock is hard, blasting and drilling are performed; if the rock is soft, directly strip them is fine; if the raw material source is below the water, use the hydrophobic operations.

mining process for making aggregate

Preprocessing Step

This stage mainly uses hammering to pre-crushing large pieces of materials in the raw sand and gravel aggregate ore, sorting the debris that is not suitable for crushing, and removing waste wood, plastic and other debris for easy processing in the next steps. In this processing process, remove the scrap iron in the aggregate.

First-level Crushing Process

First, we usually apply a crushing machine, a mobile jaw crusher to crush the raw materials in the first level. First, the vibrating feeder feeds the materials evenly to the jaw crusher. The jaw crusher uses the movement of the jaw plate to break large pieces of raw materials into smaller particles. Then, the coarsely broken materials are transported to the transfer pile by belt conveyors.

mobile jaw crusher
Mobile Jaw Crusher

First-level Screening Process

At this stage, use a circular vibrating screen to classify the coarsely broken concrete aggregate and screen particles of different sizes into materials of 5-40mm and below 5mm. The fine aggregates below 5mm can be directly used to make general C15-C20 concrete after being collected. Coarse aggregate of 5-40mm can be transported to the transfer pile for the next process.

Crawler-type Screening Machine
Crawler-type Screening Machine
Tire-type Screening Machine
Tire-type Screening Machine

Secondary Crushing and Screening Process

For the secondary crushing, use a mobile cone crusher or a mobile impact crusher to crush coarse aggregate again. Subsequently, the secondary crushed aggregate will undergo secondary screening to separate the crushed aggregate into 5-20mm high-quality recycled aggregate, which can be used for C25-C30 concrete manufacturing.

mobile cone crusher
Mobile Cone Crusher
crawler type mobile impact crusher
Crawler-type Mobile Impact Crusher
tire-type mobile impact crusher
Tire-type Mobile Impact Crusher

Sand Making Process

To meet the needs of a specific project, some crushed aggregate may need to be processed through a sand making machine to produce sand that meets specifications. After the material is screened twice, fine sand smaller than 5mm will be transported to the impact sand making machine for crushing again. After being processed by the impact sand making machine, the fine sand size can reach 0-3mm. In addition, the sand making machine can shape the materials, and the sand and gravel aggregates after processing by the sand making machine will have a more uniform particle size.

sand making machine
Sand Making Machine

Sand Washing Process

If there are higher requirements for processed sand material, the sand aggregate can be cleaned by a sand washing machine to remove soil, impurities and adhered fine particles.

sand washing machine
Sand Washing Machine

This process can be adjusted and optimized based on different project requirements and feedstock characteristics. For example, some special engineering projects may have special requirements for particle shape and composition, requiring the use of different crushing equipment or adjustment of process parameters. The goal of the entire aggregate crushing process is to obtain aggregate products that meet engineering standards through precise control and processing to ensure that the final building materials have excellent performance and reliability.

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