1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your sand and gravel pit’s profitability? Managing a highvolume aggregate operation presents distinct challenges that directly impact your bottom line. Common pain points include:
High Maintenance & Component Wear: Constant abrasion from sand and gravel rapidly degrades standard equipment, leading to frequent, costly part replacements and unplanned maintenance stops.
Inefficient Material Classification: Inconsistent sizing and poor separation of fines result in offspec product, reducing saleable yield and forcing reprocessing.
Excessive Fuel & Power Consumption: Older, nonoptimized plants consume disproportionate energy per ton of material processed, making your cost per ton unsustainable.
Permitting & Environmental Pressure: Operations face increasing scrutiny on water usage, dust control, and site footprint, requiring more efficient and contained systems.

The central question for plant managers is this: how can you increase throughput and product quality while simultaneously controlling maintenance costs and environmental impact? The solution lies in specifying the right core processing equipment.

2. PRODUCT OVERVIEW: HIGHCAPACITY SAND CLASSIFYING TANK

A modern Sand Classifying Tank is engineered for the continuous, highvolume washing, classification, and dewatering of sand within a sand and gravel operation. It replaces less efficient screw washers or cyclones for final product specification.

Operational Workflow:
1. Feed & Distribution: Slurry from a wash screen or hydrosizer is evenly distributed across the full width of the tank.
2. Settling & Classification: As material settles, weirs create multiple settling zones, separating particles by size and specific gravity.
3. Collection & Dewatering: Sized sand is collected in hoppers beneath each zone and discharged via controlled valves onto a dewatering screen.
4. Effluent Management: Fines and process water overflow weirs for further treatment or recirculation.

Application Scope: Ideal for stationary plants producing 75500+ TPH of concrete sand, masonry sand, and specialty aggregates. Best suited for operations with consistent feed material characteristics.

Limitations: Not a primary screening or scrubbing device; requires a prepared slurry feed. Performance is sensitive to consistent feed rate and water volume.

3. CORE FEATURES

Patented Weir System | Technical Basis: Laminar flow design with adjustable weirs | Operational Benefit: Provides precise control over cut points for up to four product grades from a single feed | ROI Impact: Increases saleable product yield by up to 8% by minimizing misplaced material.

AbrasionResistant Lining Package | Technical Basis: Bolton urethane or ceramic liners in highwear zones | Operational Benefit: Extends service life in critical areas by 300400% compared to bare steel | ROI Impact: Reduces annual liner replacement costs and associated downtime by an estimated 60%.

LowProfile, HighCapacity Design | Technical Basis: Optimized tank geometry for rapid settling without excessive height | Operational Benefit: Reduces required pump head pressure (HP) for slurry feed by approximately 15% | ROI Impact: Lowers ongoing power consumption for the entire washing circuit.

Modular Valve Assembly | Technical Basis: Individual airoperated pinch valves per discharge chute | Operational Benefit: Allows operators to finetune or isolate product grades without stopping production | ROI Impact: Improves operational flexibility, reducing changeover time by up to 25 minutes per shift adjustment.

Integrated Flume & Overflow System | Technical Basis: Prefabricated launder system with removable covers | Operational Benefit: Contains slurry splash, reduces housekeeping labor, and simplifies water management routing | ROI Impact: Mitigates environmental noncompliance risk and reduces daily cleanup time.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Conventional Tank) | Our Sand Classifying Tank Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner Life in Primary Wear Zones | 69 months (steel) | 2436 months (modular urethane) | +300% |
| Power Draw per Ton Processed| ~0.45 kWh/ton (system total) | ~0.38 kWh/ton (system total) |15% |
| Product Grade Consistency (Spec.)| ±2% moisture variance; ±5% gradation drift| ±1% moisture variance; ±2% gradation drift| +50% tighter control |
| OnSite Assembly Time (Typical)| 1012 mandays (field welding required)| 57 mandays (bolted modular design)| 45% |

Field data based on comparative analysis of a 200 TPH concrete sand circuit.

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: From 75 TPH to over 500 TPH of solids processing.
Power Requirements: System dependent; typical slurry feed pump requirement reduced by 1520 HP compared to taller tank designs.
Material Specifications: Tank structure from ASTM A36 steel; highwear zones lined with replaceable 25mm polyurethane or optional ceramic tiles; weirs from abrasionresistant steel.
Physical Dimensions (Model SCT250): Length: 7.5m; Width: 3m; Height (to overflow): 2.8m; Shipping Weight: ~12,000 kg.
Environmental Operating Range: Designed for outdoor installation; operating temperature range 29°C to +50°C; dusttight covers standard.

6. APPLICATION SCENARIOS

ReadyMix Concrete Supplier Sand Plant

Challenge: Needed consistent production of ASTM C33 concrete sand from variable pitrun material while reducing silt disposal costs.
Solution: Implementation of a dualcell Sand Classifying Tank with three product zones to separate coarse concrete sand, fine concrete sand, and ultrafines.
Results: Achieved >95% onspec production yield (up from 88%). Reduced silt pond loading by diverting clarified water back to the plant circuit.

Alluvial Gravel Pit Expansion

Challenge: Expanding plant capacity required doubling washed sand output without increasing the footprint permitted under county regulations.
Solution: Replaced two older screw washers with one highcapacity Sand Classifying Tank featuring a compact lowprofile design.
Results: Increased washed sand production from 120 TPH to 220 TPH within the same physical footprint while improving fuel efficiency per ton produced by 18%.

7. COMMERCIAL CONSIDERATIONS

Our Sand Classifying Tanks are offered in three primary tiers:
1. Standard Duty Model ($85k $150k): For lowerabrasion applications (<150 TPH), featuring urethane liners in primary wear zones only.
2. HeavyDuty Model ($140k $250k): For standard commercial aggregate production (150350 TPH), includes full urethane lining package and heavyduty valve assemblies.
3. Modular PlantReady Skid ($220k $400k+): Fully piped, wired,and tested skid module including tank,pump,motor starter,and controlsfor rapid integration into new plants.Optional features include advanced ceramic liningsfor extreme abrasion scenarios,custom valve automation packages,and integrated moisture sensors.Service packages range from basic parts warranties(12 months)to comprehensive annual inspectionand liner rotation programs.Financing options including equipment leasingand rentaltoown plans are available through our commercial partnersfor qualified buyers

8.FAQ

Q:What existing plant components are neededto integratea Sand ClassifyingTank?
A:The tank requiresa preparedslurryfeed.This typically comesfroma wash screenor apron feeder dischargingintoa sump.It also requiresa reliablewater supplyand pumpfor slurry transfer.Prescreeningto remove+3/8"materialis essential

Q.How does this affect my overall plant water consumption?
A:A welldesigned systemrecirculates processwaterfromthe tank's overflowback into the circuit.Field datashows thatwith proper settling,a classifyingtank systemcan reducefreshwatermakeuprequirementsby upto30%comparedto some legacyequipment

Q.Whatisthe typicalinstallationand commissioning timeline?
A.Fora bolted modularunitlike oursonsite assemblyby our crewtakesapproximatelyfive working days.Commissioningand tuningfor optimalproductgradestypicallyrequiresan additionaltwo dayswith supportfromour technicians

Q.Are spare parts readily available?
A.Criticalwear partslike urethaneliner panelsand pinchvalve sleevesare stockedin regionalwarehouseswith guaranteed48hourshipmentfor urgentdowntime situations

Q.Can this equipmenthandle veryfine materialslike fracsand?
A.SandClassifyingTanksare optimizedfor constructionaggregates(concretesand).For ultrafineclassificationrequiredin fracsandor glasssandproductionwe recommendour specializedhydrosizerrange whichoffersmore precisecutpointsbelow100mesh