1. PAINPOINT DRIVEN OPENING

Are escalating maintenance costs and unplanned downtime eroding your aggregate production margins? Plant managers and engineering contractors consistently face critical operational challenges with their crushing and screening circuits. These include premature wear on liners and screens due to abrasive materials, inefficient material flow causing bottlenecks and reduced throughput, and excessive energy consumption per ton of processed material. Furthermore, inconsistent final product gradation leads to rejected loads and lost revenue, while safety concerns around manual clearing and maintenance persist. How can you increase system availability beyond 90%, reduce your cost per ton, and ensure a consistent, spec product? The foundation of a reliable operation is not just the equipment, but purposeengineered fabrication that addresses these exact pain points.

2. PRODUCT OVERVIEW

This content details our customengineered Stationary Crushing and Screening Plants. These are permanent or semipermanent installations designed for highvolume production in quarrying, mining, and largescale construction projects. The operational workflow is engineered for continuous material processing: (1) Primary feed via dump hopper with grizzly feeder to remove fines; (2) Primary crushing (typically jaw or gyratory) for initial size reduction; (3) Conveyance to secondary/tertiary crushing stages; (4) Screening into designated product fractions via inclined or horizontal screens; (5) Stockpiling via radial stackers. This solution is scoped for highcapacity operations (200+ TPH) requiring consistent output over decades. It is not intended for smallscale, temporary sites or highly mobile applications.

3. CORE FEATURES

Modular Skid Design | Technical Basis: Unitized, preassembled structural frames | Operational Benefit: Reduces field installation time by up to 40%, ensures precise alignment of crushers, feeders, and screens prior to shipment | ROI Impact: Faster commissioning accelerates revenue generation and lowers contractor costs.

HeavyDuty Plate Fabrication | Technical Basis: CADoptimized stress analysis on wear zones using AR400/500 steel | Operational Benefit: Extends structural service life in highvibration environments, minimizes cracking and fatigue at welds | ROI Impact: Lowers lifetime structural repair costs by an estimated 60% versus standard fabrication.

Optimized Chute & Hopper Geometry | Technical Basis: Discrete Element Modeling (DEM) analysis of material flow | Operational Benefit: Eliminates plugging and reduces dust by controlling material velocity and trajectory, ensures even feed across crusher cavity and screen decks | ROI Impact: Increases overall plant throughput by 815% by removing flow bottlenecks.

Centralized Walkways & Access Platforms | Technical Basis: ANSI/OSHA compliant design with integrated safety gates & ladder systems | Operational Benefit: Provides safe, 360degree access for routine maintenance, liner changes, and inspections | ROI Impact: Reduces downtime for servicing tasks by improving technician efficiency and mitigating safety incident risk.

Integrated Dust Management Points | Technical Basis: Prefabricated shrouding with flanged connection points for dust collection systems | Operational Benefit: Simplifies the integration of baghouses or spray systems at major transfer points | ROI Impact: Facilitates regulatory compliance and improves site working conditions without costly field modifications.

Vibration Isolation Mounting Systems | Technical Basis: Isolator pads or spring mounts calibrated to dynamic loads of vibrating screens & feeders | Operational Benefit: Decouples vibration from the primary structure, reducing stress on support steelwork and adjacent equipment | ROI Impact: Cuts longterm structural maintenance requirements and improves reliability of connected conveyors.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Fabrication | Our Stationary Plant Fabrication Solution | Advantage (% improvement) |
| : | : | : | : |
| Structural Fatigue Life| Standard A36 steel in highstress areas| AR400 steel reinforcement at all critical stress points identified by FEA| +150% estimated service life |
| OnSite Installation Labor| Fieldfit assembly of major components| Preassembled, aligned modules bolted together on foundation| 40% labor hours |
| Material Flow Efficiency| Conventional chute design based on legacy layouts| DEMoptimized chutes & hoppers for specific material characteristics| +12% average throughput gain |
| Planned Maintenance Duration| Limited access requiring scaffold or mobile platforms| Fullperimeter OSHA platforms & walkways integrated into design| 30% time for liner inspections |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Engineered for 200 – 2,500 Tons Per Hour (TPH), depending on circuit configuration.
Power Requirements: Designed to integrate with clientsupplied primary crusher motors (100600 HP), screen drives (30100 HP), and conveyor systems. Full electrical load analysis provided.
Material Specifications: Primary structure ASTM A36 carbon steel. Wear liners in hoppers, skirts, and chutes from AR400 or AR500 abrasionresistant steel. Optional Hardox® or ceramic lining available.
Physical Dimensions: Fully modular; individual skid dimensions optimized for transport logistics. Typical primary crusher module footprint: 10m L x 6m W x 5m H.
Environmental Operating Range: Fabricated for ambient temperatures from 29°C to +45°C (20°F to +113°F). Designs account for local seismic zones and wind loads as required.

6. APPLICATION SCENARIOS

Granite Quarry Expansion | Challenge: A southeastern US quarry needed to increase basalt production by 60% but had space constraints limiting plant footprint expansion.| Solution: We designed a compact tertiary crushing & screening tower using a vertical shaft impactor (VSI) on an elevated skid feeding directly onto multislope screens below.| Results: Achieved required capacity within the existing footprint; DEMoptimized chutes reduced VSI wear part costs by 18%; plant availability reached 94%.

Iron Ore Processing Circuit Upgrade | Challenge: Existing transfer points between primary crusher and secondary cone were causing chronic plugging (~3 hours daily downtime) and excessive dust emissions.| Solution: Fabrication of replacement primary discharge chute, secondary feed hopper, and enclosed conveyor transfer tower with integral dust collection flanges.| Results: Plugging incidents eliminated; captured dust returned to process stream improved yield; annual downtime reduced by over 750 hours.

7. COMMERCIAL CONSIDERATIONS

Pricing is projectspecific based on scope but generally falls into three tiers:
1. Component Fabrication: For single elements like replacement chutes, hoppers, or access systems.
2. Module Fabrication: For complete skidmounted sections (e.g., a screen tower module with conveyors).
3. Turnkey Plant Fabrication: Full structural design,fabrication,and mechanical assembly of the crushing/screening circuit.
Optional features include advanced wear monitoring systems,custom cladding,and automated lubrication system integration.Service packages range from basic drawingsasbuilt documentation to comprehensive multiyear inspection programs.Financing options through thirdparty partners can structure capital expenditure into predictable operational payments.

8. FAQ

Q1: Is your fabricated structure compatible with our existing crusher brand X?
A1: Yes.All our fabrication is customengineered.We require the certified mechanical drawings from your OEM equipment supplier to ensure perfect interface tolerancesand load support.

Q2: What is the typical impact on installation schedule?
A2: Field data shows our modular approach reduces onsite mechanical erection time by approximately40%.The majority of fitup,welding,and alignment is completed under controlled shop conditions.

Q3: How do you handle design revisions during fabrication?
A3: We operate under a formal change order process.Any clientinitiated revision after final drawing approvalis evaluatedfor impacton scheduleand costbefore proceeding.This structured approach protects both parties' interests.

Q4: Can you provide fatigue life calculationsfor the structure?
A4. Yes.Finite Element Analysis(FEA) reportsfor highstress areas are standard deliverableswith our designs.This provides an engineering basisfor expected service lifeunder defined loading conditions

.Q5. What warranties applyto your fabrication work?
A5. We providea standard warrantyagainst defectsin materialsand workmanshipfor a periodof [Industry Standard,e.g.,18 months]from commissioning.Structural integritywarrantiesare also availablebasedon project scope