1. ABERTURA ACIONADA POR PAINPOINT

Are you managing inconsistent aggregate output, struggling with unplanned maintenance costs, and facing pressure to improve site safety and operational efficiency? Para gerentes de fábrica e empreiteiros de engenharia, a suboptimal stone crusher plant directly impacts your bottom line through excessive downtime, alta frequência de substituição de peças de desgaste, e gradação imprevisível do produto final. These challenges lead to missed project deadlines, cost overruns on raw material processing, and increased labor for manual sorting and recrushing.

Consider these questions: Is your current crushing circuit failing to adapt to varying feed material hardness without significant manual intervention? Are you experiencing vibrationrelated failures in structural components that halt production for days? Is the total cost of ownership for your crushing equipment undermining your project profitability? A solução não está apenas em um britador, mas em uma engenharia holística stone crusher plant fabricator system designed from the ground up for reliability and precise output control.

2. VISÃO GERAL DO PRODUTO

This product details a customengineered, stationary or semimobile stone crusher plant—a complete crushing and screening circuit fabricated as an integrated unit. Fabrication involves the design, engenharia, and manufacturing of the plant’s structural framework, cai, plataformas, and conveyor supports to house and interconnect primary, secundário, and tertiary crushers with screens and material handling systems.

Fluxo de Trabalho Operacional:
1. Alimentação Primária & Esmagamento: Runofquarry (ROQ) material is fed via dump truck or loader into a robust hopper leading to a primary jaw or gyratory crusher for initial size reduction.
2. Transferência de Materiais & Triagem: Crushed material is conveyed to a primary screen (por exemplo, vibrating scalper) which separates sized product from oversize material requiring further reduction.
3. Secondary/Tertiary Crushing Circuit: Oversize material is routed via controlled transfer points to secondary (por exemplo, triturador de cone) or tertiary crushers for precise shaping and final size reduction.
4. Final Sorting & Estoque: Correctly sized aggregates from each crushing stage are conveyed to designated stockpiles via radial stackers or fixed conveyors.

Escopo de aplicação: Ideal for mediumtolarge scale aggregate production for road base, agregado de concreto, e lastro ferroviário. Suitable for quarrying limestone, granito, basalto, e cascalho do rio.
Limitações: Not designed for portable/mobile trackmounted applications requiring daily relocation. Full optimization requires detailed feed material analysis and sitespecific engineering.

3. RECURSOS PRINCIPAIS

Design modular de deslizamento | Base Técnica: Unitized structural fabrication with integral lifting points | Benefício Operacional: Reduces onsite assembly time by up to 40%, permitindo um comissionamento mais rápido | Impacto do ROI: Lower labor costs during installation and easier relocation within a site
Lined & Reinforced Transfer Points | Base Técnica: Aço resistente à abrasão (AR400/500) liners in highimpact zones with rubber dampening | Benefício Operacional: Minimizes material hangups and reduces noise; extends liner life by over 60% | Impacto do ROI: Decreases downtime for chute maintenance and reduces spare parts inventory cost
Passarelas Centralizadas & Access Platforms | Base Técnica: Ergonomic design per ISO 14122 safety standards with nonslip grating | Benefício Operacional: Permite segurança, rapid inspection of crusher jaws, decks de tela, and conveyor idlers | Impacto do ROI: Improves preventative maintenance adherence and reduces risk of safety incidents
Engineered Dust Suppression Integration | Base Técnica: Preplumbed manifolds with strategically placed nozzle ports at crusher discharges & pontos de transferência | Benefício Operacional: Allows direct connection to water supply or fog systems for immediate dust control compliance | Impacto do ROI: Mitigates environmental noncompliance risks and improves operator health
Vibration Isolation Crusher Bases | Base Técnica: Decoupled crusher mounting platforms with isolator pads or spring assemblies | Benefício Operacional: Absorbs dynamic loads preventing fatigue cracks in the primary support structure | Impacto do ROI: Elimina reparos estruturais dispendiosos; ensures longterm frame integrity

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Fabricação padrão da indústria | Our Stone Crusher Plant Fabrication Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Tempo de montagem no local | Soldagem de campo & boltup of individual components | Preassembled modules with predrilled connection points | 3540% Mais rápido |
| Vida de fadiga estrutural (at welds) | Standard mild steel fabrication at stress points | FEAoptimized design with reinforced nodes & stressrelieved welds | 50% Longer (Estimado) |
| Eficiência do Fluxo de Materiais (Transfer Points)| Fabricated chutes often require periodic hammering/clearing| Computermodeled flow geometry with cascading liners & inspection doors| Reduces blockages by ~70% |
| Planned Maintenance Accessibility| Often requires scaffolding or temporary platforms| Integrated permanent access to all major wear part locations| Cuts inspection time by 50% |

5. ESPECIFICAÇÕES TÉCNICAS

Plant Capacity Range: Configurável de 150 TPH para 800+ Taxa de transferência de TPH.
Requisitos de energia: Projetado de acordo com a especificação do cliente; includes integrated cable trays and main distribution panel mounting points. Typical range: 200kW 1.2MW total connected load.
Especificações de materiais: Estrutura primária: S355JR grade steel. Highwear areas lined with AR400/500 abrasionresistant plate (10mm25mm thickness). Passarelas: Galvanized steel grating.
Dimensões Físicas: Customengineered per layout. Common modular skid sizes up to 12m L x 4m W x 4m H for transportability.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Paint systems include primer, midcoat, and polyurethane topcoat for C4 corrosion resistance per ISO 12944.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Challenge A quarry needed to increase production of railway ballast (40mm+20mm cubical aggregate) but had space constraints preventing a traditional dispersed plant layout.
Solution Implementation of a compact, threestage crushing plant fabricated on two primary skids—one housing the primary jaw crusher feeder module, another housing the secondary cone crusher screen tower—connected by short fielderected conveyors.
Results Plant was commissioned in 11 days postfoundation readiness. Achieved consistent ballast product shape (>85% cubicidade), meeting strict rail specifications without a dedicated shaping crusher stage.

Limestone Aggregate Plant Modernization

Challenge An existing plant suffered from chronic downtime due to clogged transfer chutes between the secondary cone crusher discharge screen return conveyor.
Solution Replacement of the entire secondary circuit’s fabricated steelwork including computermodeled transfer chutes rock boxes lined with interchangeable rubber ceramic composite liners.
Results Material hangups were virtually eliminated Wear part replacement interval on chute liners extended from months years reducing annual maintenance costs by an estimated

7 CONSIDERAÇÕES COMERCIAIS

Pricing is projectspecific based on scope complexity capacity However standard tiers exist:

Basic Structural Fabrication Package Includes primary support structures walkways ladders basic chutework Client supplies all process machinery (crushers screens)

Engineered Turnkey Module Package Complete design fabrication integration of modules around specified OEM machinery including conveyors dust suppression plumbing electrical cable management

Optional Features Advanced automation sensor mounting packages automated lubrication system runs insulated enclosures for arctic operations premium coating systems

Service Packages Include extended warranty on structural fabrications installation supervision commissioning support

Financing Options Available through partnered financial institutions covering both equipment lease options

8 Perguntas frequentes

What information is required provide quote?
We require your target feed material analysis desired final products capacities existing layout drawings any preferred OEM process equipment brands ensure compatibility our fabrication

How does fabricated plant differ skid mounted portable plant?
Our plants are designed permanent semi permanent installation emphasizing durability capacity over mobility They offer superior structural integrity vibration management compared portable units which prioritize transport weight

Can you integrate existing crushers screens into new fabricated structure?
Yes retrofit projects are common We engineer new support structures transfer points seamlessly connect your existing core machinery extending its service life improving its performance

What typical lead time from order commissioning?
For standard capacity plants lead time typically ranges months depending complexity This includes detailed engineering procurement fabrication factory acceptance testing

Do you provide civil foundation drawings?
Yes we supply comprehensive foundation anchor bolt layout drawings load data certified professional engineer facilitate accurate site preparation our team