Rock crusher equipment serves as the fundamental platform in transforming the raw rocks into regular gravel for use in construction and other landscape or pavement work projects. The rock crushing process, which entails high-quality rock crusher at its core, is an indispensable process in the production of sand and gravel, yard transformation, and construction of infrastructure. The process of producing the finished gravel requires the use of a specialized rock crusher system for carrying out operations of graded crushing, size reduction and shaping, cleaning, and dusting. There are two types of well-developed processing systems: manual small-scale rock crushing process without the use of any equipment and industrialized large-scale rock crushing process with the aid of the complete MP
rock crusher production system.
Pre-Production Preparation for Standard Rock Crusher Processing
Raw Material Screening and Pre-Treatment
For rock crusher processing, the quality of the raw rock material is paramount since it affects the quality of the gravel produced. It is therefore important to select strong, sound rock such as granite, bluestone, river stone, and basalt for the process of rock crusher processing. Rock which is highly weathered, highly clayey, weak, and loose should not be used.The rock crushing machinery is susceptible to contamination by impurities, which makes the cleaning process of the raw rock very important. Properly clean all impurities such as mud, weeds, sediments, soft soils, and tree bark on the surface of the raw rock using shovels or high pressure water gun. This vital pre-processing stage will keep foreign materials out of the rock crusher compartment.The crushing plant has a predetermined maximum size of feed input for avoiding damage to the machine. Where rocks exceed that size, then perform manual pre-breaking of the rocks to make sure that the rock sizes conform to the required specification for the input of the rock crushing machine.
Site Layout & Safety Guidelines for Rock Crusher Operation
Standard operating conditions should be met during rock crushing process. Choose the level and strong land area, which is ventilated and open, for all rock crusher production process. The place where the operation is being carried out must be located away from the residential place, electric cables, and any flammable explosives. It is necessary to properly demarcate the land into raw material stockpile, rock crusher working area, and finished stone stockpile.Mechanical operation of rock crushing machinery comes under hazardous working environment, thus safety measures become a necessity. All employees are supposed to use safety goggles, crash proof helmets, non-slip shoes, and strong gloves. Dust-protection masks need to be worn by professionals during extended periods of rock crusher operations. Clear the workplace from debris and rocks before rock crushing process.
Tool & Rock Crusher Equipment Matching by Production Volume
The rock crusher equipment set must be based on the capacity of the process to make it economical and efficient. Here we give two sets of compatible tools and rock crushing solutions depending upon different applications:Low household or low capacity processing: Sledge hammer, shovel, coarser and finer screens, water vessel and high pressure water pump (no need of any industrial rock crusher)Large scale engineering processing in batches:MP Jaw Rock Crusher (primary coarse crushing),
MP Impact Rock Crusher (fine crushing and shaping), Vibrating screen and conveyor belt (complete rock crushing line)
Core Gravel Crushing Processes: Manual VS Professional Rock Crusher Production
Mode 1: Manual Crushing for Small Projects (No Rock Crusher Needed)
Rock crusher machines are not required for small-scale and low demand work. The manual crushing process does not require rock crusher machine, easy to operate and economical, and is suitable for small-scale construction projects like courtyard paving, backyard filling, and flower bed restoration projects with limited gravel requirement.Step 1: Fix the raw rocks Fixed the raw rocks firmly on a solid cement floor or stone surface in order to prevent any shaking or deviation. An iron plate can be used at the bottom to prevent any harm to the ground and also enhance the manual crushing process without rock crusher.Step 2: Coarse crushing Crushed the raw rocks by hitting the central and weak part of the rocks using a sledgehammer in order to produce medium-size pieces of rocks 5-10 cm. It should be done in a smooth and layered manner, as it will reduce gravel splashing.Step 3: Fine crushing Further crushing is done to produce standard size gravel 1-3 cm according to requirement. Excess stone powder is removed from the process.
Mode 2: Mechanical Graded Crushing (Mass Production With Complete Rock Crusher Line)
The MP rock crusher production line makes the production of the standardized gravel for engineering work possible. The industry level production of the gravel takes advantage of the scientific two-stage process of crushing the rocks through rock crusher. The two sets of professional rock crushers used together create uniform size particles with neat edges and great structural strength for the use in infrastructure construction, road construction, and concrete batching projects.Primary step: Coarse crushing through jaw rock crusher The pre-treated stones will be transported evenly to the jaw rock crusher using the conveyor belt. The MP jaw rock crusher utilizes the principle of the jaw plate extrusion to crush the big raw stones to small sizes of 3-8 cm coarse aggregate.Secondary step: Fine crushing and shaping of gravel through impact rock crusher The products of the first stage will be passed to the impact rock crusher. The high speed impact and collision grinding in the MP rock crusher will reduce the coarse stones to smaller sizes and smooth out all the sharp edges and corners of stones to create standard gravel particles.
Particle Screening & Grading for Rock Crusher Processed Aggregates
The materials crushed by rock crushers have varying sizes and include excessive stone powder. The process of screening and grading after the rock crusher’s primary crushing becomes inevitable to separate qualified standard gravel from the waste residues.
Manual Screening
Semi-finished materials from the rock crushers can be separated through manual separation methods where double layer screens can be used. The coarser mesh will act as a filter to the oversized and unqualified stones that remained after primary crushing by rock crushers. On the other hand, the finer mesh will work in filtering the stone powder and fine sand. Manual shaking of screens can be done to classify the material where the unqualified oversized materials will be sent back to the rock crushers for second crushing.
Mechanical Screening
Rock Crusher Production Lines equal Mechanical Vibrating Screening for automatic batching classification. With large scale production using complete MP rock crusher plant, use multi layer vibrating screening machine for automatic classification of various gravel sizes (1-2cm, 2-3cm, 3-5cm etc). Gravel that meets specifications will be conveyed to appropriate storage locations, while oversize and non-conforming material will be automatically fed back to the rock crusher plant for recycling process.
Dust Removal, Cleaning & Finishing of Rock Crusher Processed Gravel
The process of rock crusher crushing and supporting screening leads to the formation of huge quantities of stone powder and floating dust. The latter adhere to rock crusher processed gravel surfaces and reduce the adhesion between the gravel and the cement mortar, thus deteriorating construction quality. Professional cleaning and dust removal are necessary after the rock crusher operation.Rock crusher produced products should be cleaned depending on their quantity. Small batches of manually processed gravel should be washed using high pressure water guns, whereas industrial
MP rock crusher processing lines need washing and dust removal equipment to thoroughly get rid of dust and dirt adhered to the rock crusher processed gravel surfaces.Processed rock crusher gravel holds some residual moisture after being washed. It should be laid out flat on a clean site to let it air dry to evaporate any remaining moisture. Otherwise, caking and mold formation due to moisture will lead to deterioration of the rock crusher finished product quality.Finished gravel produced by rock crusher requires classified storage. Rock crusher processed and air dried gravel should be stacked in zones according to the particle size and enclosed in order to prevent additional soil and rain contamination.
Standard Safety Operation Rules for Rock Crusher & Crushing Work
1.Manual crushing activities without a rock crusher need strong safety protection. One must not hit rocks directly because of gravel splashing to one's face and eyes; keep safe distances when working in multiple individuals and no cross construction.2. When operating rock crushers through mechanical means, stick strictly to operational regulations of machinery. The feeding process needs to be continuous and stable. Do not place hands and head near the feeding entrance and discharge entrance of the rock crusher. Do not check or clean any clogged material when the rock crusher is in operation; always shut down machinery and stop power supply when carrying out maintenance activities.3. Full dust protection process needs to be undertaken throughout rock crushing operations. Put on dust proof mask all the time during working to avoid breathing problems caused by rock dust inhalation.4. One must totally reject heavily weathered soft rocks and rocks with a lot of impurities as the raw materials since these materials will make the quality and structure of produced gravel unqualified for building purposes.
