CONCRETE RECYCLING

Less sand and much coarse grain

betonrecycling

In high quality

FROST LAYER AND GRAVEL BASE LAYER

In times of increasingly scarce raw materials, it is increasingly important to reuse the available construction waste with maximum quality in order to obtain high-quality RCL material at the end of the process chain. When crushing rubble waste usually high fines and high levels of crushed sands are produced, which can prevent the reuse of this recycled material. Monitoring the grading curve is therefore essential to ensure consistent quality. In particular, the proportions of the smaller grain fractions should be smaller, so that the legally prescribed limits for frost layers and gravel base layers are not exceeded by the handling and compression of the RCL gravel. Only then can the requirements for water permeability and frost resistance be guaranteed even after complete use of it.

Not to be neglected are the compaction properties, which are more advantageous if the grain composition contains more coarse grain fractions. In addition to the improved load-bearing capacity, this also improves the paving quality and shortens the paving time.

LITTLE SAND AND A LOT OF COARSE GRAIN

The gentle crushing process produces only a minor portion of the smaller grain sizes. This gives you more coarse grains, which take on an important function for the support structure, and achieves an excellent load capacity and compressibility of the material. The largest grains are supported by the smaller grains.

The low level of sand or fine particles ensures excellent water permeability and guarantees important antifreeze properties. Depending on the feed material and processing, it may even happen that the amount of added sand have to be increased, so that the usually excess sand content from other treatment processes are utilized and do not need to be landfilled.

Betonrecycling
Betonrecycling

Concrete granules

AS AGGREGATE FOR CONCRETE

Due to the small proportion of fractions smaller than 2 mm, the double-roll crushing technology with special crushing tools is excellently suited for the production of aggregates for concrete. For feed grain sizes of e.g. 22/100 mm, a product grain size of less than 22 mm can be produced with a sand content of between 20% and 25%.

Beton Vorbruch
Concrete recycling - primary stage
Concrete recycling - secondary stage
Brechergebnis
Crushing result

CONCRETE PRIMARY CRUSHING

Efficient crushing of large feed material

Beton Vorbruch

Concrete blocks

WITH STEEL REINFORCEMENT

When defining the feed material in a crushing plant, edge length and piece size are important factors to ensure the functionality of the entire crushing process. Until now, the size of the acceptable feed material in the crushing plant is limited, which in return causes the demolition company high costs for pre-crushing. The typical maximum feed size in crushing plants for crushing rubble and concrete is 700 mm. With larger feed items, the crusher can be damaged or clogged, or wear increases disproportionately.

With the primary crusher from Crush + Size, this limitation can be largely eliminated. Feed sizes with edge lengths of up to 1,700 mm and thicknesses of approx. 700 mm can be processed quickly by the primary crusher.

PROCESS PROPERTIES

Characteristic for the primary crusher are the direct and efficient feed as well as the rough pre-crushing of the feed material to a grain size of 0 – 250 mm. A pre-screening is not necessary. Smaller grain sizes pass through the crushing chamber without being further crushed. The material feed can be carried out directly or by means of a vibrating trough.

The crushing gap can be adjusted hydraulically. The hydraulic gap adjustment is also the heart of the overload protection system when foreign bodies that cannot be crushed have to pass through the crushing chamber. In this case a roller is pushed away and immediately after this process moves back to its starting position.

DRC

ECONOMY AND ENERGY EFFICIENCY

With the help of a primary crusher of the type DRC 900-20, a large part of the preparatory work of the feed material can be saved. This preparatory work is otherwise carried out with great effort by crawler excavators with attachments such as pulverizers and hydraulic hammers, which also significantly increases the undesired fine fraction in the feed material and the final product.

The average power requirement of the Crush + Size primary crusher is extremely low. The energy consumption during preparatory work by an excavator with hydraulic attachments is many times higher

With a throughput of 200 t/h, which can be achieved with the primary crusher DRC 900-20, the profitability calculation clearly speaks in favour of using the primary crusher of Crush + Size.

Another advantage of this primary crusher is that fine grain is only produced in small quantities. This enables the production of a coarse-grained, high-quality recycling material in the further crushing process.

CONCRETE RECYCLING USEFUL GRAIN

Valuable secondary crushing

Concrete recycling secondary stage

COARSENESS AND SEPARATION OF SUBSTANCES

A pre-crushed grain reaches the secondary crusher and is broken into a grain band with a high proportion of coarse grain. The concrete is completely separated from the reinforcing steel. Thanks to the gentle process, there is little wear and tear and dust exposure is kept to a minimum. Grain sizes of 0-63 mm can be achieved economically.

PROCESS PROPERTIES

The direct feed and the high crushing ratio are decisive also for the high efficiency of the secondary crusher. A pre-screening is not absolutely necessary. Smaller grain sizes pass through the crushing chamber without being further crushed. The material can be fed into the crusher directly or by means of a vibrating chute.

The crushing gap is hydraulically adjustable. This adjustability is also the heart of the overload protection. If foreign bodies that cannot be crushed have to pass the crushing chamber, the roller is pushed away and immediately after this process it moves back to its starting position.

DRC-Zweiwalzenbrecher | DRC-Double Roller Crusher

ECONOMY AND ENERGY EFFICIENCY

Due to the special tool contour and the synchronized roller rotation, the crushing tools penetrate the feed material in such a way that the foreign matter is effectively exposed by pressure and shearing. The steel content can be separated with a high degree of purity using a steel separator.
An important feature for the crushed material is the high proportion of valuable grain. A target grain size of 0-63 mm is typical for secondary size reduction. In order to achieve the highest possible proportion of valuable product, it is manufactured in a circular process.
Foreign substances such as wood or plastic are not shredded any further and can then be quickly removed from the material flow using common separation processes. In addition, the foreign matter is not processed into undesired fine fractions, which would contaminate the crushed material to a greater extent.

CRUSHING RESULT

Our crusher for coarse material offering detailed solutions

At a glance

PROPERTIES OF THE CRUSHED PRODUCT

Grain sizes as required 0-22; 0-32; 0-45; 0-56; 0-80; 0-120; 0-170; smaller grain sizes upon request
Grading curve even Distribution of the grain fraction is even;
higher amount of large fractions
Oversize material hardly present Crushing space is geometrically limited in the 3D space
Dust proportions very low ratio Depending on the crushed material
Crushed sand low amount Depending on the crushed material
Steel reinforcement separation of the materials Concrete is separated from steel reinforcement
Foreign body unproblematic Roller escapes and released crushing space;
continued production without interruption

GRAIN DISTRIBUTION AND GRAIN FORM

Betonrecycling

Characteristic grain distribution with higher amounts of coarse fractions

OTHER INDUSTRIES

The right crushers to meet your requirements

Brechen von Kalkstein | Crushing limestone
Limestone
Sandherstellung | Sand production
Sand and Grit
Rubble recycling
Asphalt