Manufacturing Sand For Concrete With Proman Crushers

Manufacturing Sand For Concrete With Proman Crushers

Sand is one of the most important ingredients in deciding the strength and quality of concrete. The success and failure of a construction depends significantly on the quality of sand used. Sand that ensures strength and beauty of construction possesses rounded and cubical particles. Such sand has full range of well-graded size that finishes smoothly. Experts have recommended technical parameters and methods to judge the quality of sand. Fineness Module (FM) of sand is one such important parameter in judging quality of sand.

Sand with the required FM ensures good workability and finishing properties in the concrete mix. The sand must have cubicle particles for all sieve sizes and must be washed. Materials which can be crushed to make sand are limestone, granite, basalt, gravel, andesite, sandstone, silica, quartzite. In short, and any sound stone used for construction material can be crushed to produce sand.

The Parameter of FM was developed to indicate the properties of sand in a numerical value. The fineness modulus indicates the relative fineness or coarseness of a sand sample. The accumulated percentages retained on numbers 4,8,16,30,50, and 100 screen sieves are added up and the total divided by 100 giving FM number. The ideal manufactured sand grading yields a FM number of 2.76. Commercially, FM number of 3.0 or less is acceptable.

Sand Manufacturing

PROMAN, manufactures crushers which produce manufactured sand.

Manufactured sand which is produced by crushing aggregates has a tremendous demand as well and PROMAN is one of the world leaders in this segment.

PROMAN focuses on the following:
  • Major accounts in the mineral and contractor segment
  • Sand plants
  • Road and Dam contractors in India and neighboring countries
  • Mines and Mineral Processing Industries
PROMAN has a state-of-the-art factory in Bangalore to manufacture Crushing, Screening and Sand Washing equipment to supply aggregates and sand to quarry and mineral sectors. PROMAN manufactures Vertical Shaft Impact Crushers in collaboration with M/s REMco, USA who are leaders in reduction technology. PROMAN-REMco machines produce cubical, well-graded, sound, mid-range aggregates, specification sand and other fine sizes.

In collaboration with LIPPMANN of USA, PROMAN manufactures heavy duty primary Jaw Crushers which have capacity to produce? 100 to 500 tons per hour. PROMAN also manufactures PROcone a cone crusher which does both secondary and tertiary crushing.

PROMAN has collaboration with M/s Finedoor, United Kingdom for manufacturing screens and grizzly feeders in India.

PROMAN in collaboration with M/s Aggregate Equipment Industries, USA manufactures the unique Ortner for the removal of fines from the product available from crushers. PROMAN has flexibility in the form of PROMO series mobile crusher and PROMAN-Striker range of Tracked Machines.

Custom Engineered Equipment For Sand Manufacturing

Manufacturing Sand For Concrete With Proman Crushers
REMco Sandmax VSI is exclusively designed to produce sand and other fine products. It produces manufactured sand from hard abrasive rock at an affordable cost. It can be custom engineered to meet specific sand production requirements. The REMco Sandmax VSI offers unmatched advantage in terms of power consumption. Most VSI’s in the market have traditional 3 port rotors which is a power hungry design. With 3, 4, 5, 6 port REMco rotors pull in more material through the rotor and ensure efficiency in terms of power consumption. Typically, the power consumption in a REMco VSI is in the range of 1 to 1.4 HP per ton which is quite close to the power cost of a tertiary cone. The REMco VSI offer shape and grade advantage and the material goes 100% through the rotor whether it is “Rock on Rock” or “Rock on Anvil” design. The flexibility of the rotor speed, type of chamber and rotor offers greater control on gradation.

PROMAN-REMco VSIs are crushers and not just shapers. Better design and material technology guarantee lesser wear-cost per ton. Higher feed size upto 75 mm is possible with PROMAN-REMco Sandmax VSI.

This type of VSI has wider control of speed for efficient operation. As the graded rocks are fed to the crusher, each particle experiences a rapid acceleration and deceleration in microseconds. This fills the crushing chamber with a violent rock cloud. Depending on desired product, the crushing forces applied can be controlled by the operating speed of the machine. The speed control when combined with a variety of crushing chamber features results in optimum crushing efficiency for the power applied.

PROMAN-REMco VSIs are easy to maintain as they can be serviced from top. The tips are “insert” type unlike the traditional “bolt on” type used by others. Lubrication is also easy as greasing can be done through centralized greasing block. These VSIs possess impressive structural integrity as they are heavier and built like crushers and not just shapers.

Dual Purpose Aggregate Plant

The plant for concrete sand manufacturing that meets the IS: 383 (Zone I and II) specifications requires an elaborate flow circuit design. The equipment consists of surge bin, feeder, automation, screen, washing and blending gates.

Surge bin is necessary to provide a ready large quantity of new feed to the crusher. The surge bin protects the crushed sand circuit from the production irregularities in other parts of the crushing plant. The surge bin should be filled with clean well graded material having a maximum of 3" (75 mm) or any smaller size of sound stone or gravel.

A feeder is essential as it controls the rate of new feed introduced to the sand circuit. A feeder allows optimum and continuous flow or new feed. Belt feeders are preferred because of their linear capacity and control. Electro mechanical vibrating feeders are also acceptable but provide less control at maximum feed rates requiring that they be oversize.

The addition automation increases sand production by 10% to 30%. Automation eliminates the human factor lowers operating cost and ensures maximum feed rate to utilize all the connected crushing power. Automation ensures continuous crusher discharge grading.

The vibratory screen is designed for fine screening below 3/16" (4.75 mm). It may be 2 or 3 deck type. It can be horizontal or inclined style. It must be conservatively sized, preferably oversized.

Conclusion

Natural sand is depleting at a very fast pace and efforts are being made to conserve it. The major solution to this problem is to use manufactured sand produced by crushers such as those provided by PROMAN.

Manufacturing concrete sand is proving to be the best solution that balances the demands for environment protection and higher economic growth.

PROMAN provides crushing solutions and it believes that its equipment is a part of the total solution which involves the process, the application and the system. It spends a lot of time to understand customer requirements and ensure that it educates the customers so that they take the right decision PROMAN’s u.s.p. is to provide innovative crushing solutions with its collaborations in technology from world class crushing and screening equipment. PROMAN is known for providing crushing solutions, which are customized to the segment or industry.
NBM&CW September 2010
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