Who can use it?
Employed in the construction, mining, aggregate, recycling, and road construction industries for base layers in road construction, fill material in large concrete structures, coarse aggregate for various projects, intermediate-sized aggregates in ore dressing, recycled aggregate for larger concrete structures, and intermediate road layers for load distribution and stability.
Benefits of the crusher?
Superior Stability: Fixed installation in concrete provides robust foundation, minimizing vibration and enhancing safety.
Extended Lifespan: Reduced wear from stationary setup ensures longer equipment reliability and lower maintenance.
Increased Capacity: Fixed plants can handle larger crushers and screens, optimizing production efficiency.
Environmental Compliance: Integrated dust and noise control measures are easier to implement, meeting regulatory standards.
Long-term Cost Savings: Lower operational costs over time with reduced fuel use, maintenance, and downtime.
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Suitable for a wide range of materials and applications, from aggregates to recycling.
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Built to withstand harsh conditions and ensure long-term reliability in diverse environments.
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Optimized energy efficiency to reduce operating costs and environmental impact.
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Intuitive controls and ergonomic design for ease of use and increased productivity.
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Access to expert technical support, parts availability, and service to minimize downtime.
Why buy from HPPA?
ITD Cementation
HPPA International's civil-mounted crushing plant significantly boosted our mining operations, increasing our ore processing capacity by 35% and reducing downtime by 20%, thanks to its superior efficiency and robust design.
Tantia Constructions
Our road construction project saw a 40% improvement in material recycling with HPPA's crusher, which outperformed competitors by offering 30% more operational uptime and unparalleled after-sales service.
How does the crusher work?
Civil mounted crushing plants are commonly used in the construction and demolition industries to crush materials on-site. They operate by reducing large pieces of concrete, asphalt, or other demolition debris into smaller, more manageable sizes. Here’s a basic overview of how a civil mounted crushing plant works:
Feed Hopper:
Raw materials are fed into the crusher through a vibrating feeder or a grizzly feeder. The feeder distributes the material over the entire length of the crusher.
Primary Components:
Jaw Crusher -
Movable Jaw: The movable jaw is attached to a swinging lever, which is connected to an eccentric shaft. This shaft rotates and moves the movable jaw, causing the material to be crushed.
Fixed Jaw: The fixed jaw is stationary and acts as a support for the movable jaw. It provides a surface against which the material can be crushed.
Toggle Plate: The toggle plate is a mechanism that helps to transmit power and protect the crusher from overloading. It is connected to the movable jaw and helps in adjusting the size of the discharge opening.
Impact Crusher -
Rotor: The rotor is a high-speed rotating component that throws the material against a stationary surface, breaking it into smaller pieces.
Impact Plates: These are stationary surfaces that the material impacts and breaks against.
Cone Crusher -
Cone: The cone is a rotating component that crushes material between a gyrating spindle and a concave hopper.
Mantle: The mantle is a moving part that gyrates in an eccentric motion, crushing the material against the cone.
Crushing Process:
Initial Crushing: Large pieces of material are fed into the primary crusher (typically a jaw crusher) where they are initially crushed into smaller sizes.
Secondary Crushing: The material from the primary crusher is conveyed to secondary crushers (impact or cone crushers) for further size reduction.
Screening: The crushed material is then passed through vibrating screens that separate it into different size fractions.
Recirculating: Oversized material that does not pass through the screens is recirculated back to the crushers for further reduction.
Discharge:
The final, crushed material is discharged through the bottom of the crushers. It is then collected and transported via conveyor belts to storage piles or directly to the next phase of the construction process.
Select the crushers specifications
Civil Mounted <40MM Single Stage 150TPH
Standard Offer
Percentage of out put products with a possibility of variation of 5 to 10% as per requirement | - 40 + 25 mm = 15 % - 25 + 10 mm=55% - 10 + 5 mm =15% - - 5 + 0 mm=15 % (The percentage may be change according to site & material condition ) |
Primary Crusher | 36”X28” Heavy duty single Toggle Jaw Crusher – 1 No |
Secondary Crusher | 48”x8” Heavy duty single Toggle Jaw Crusher– 3 Nos. |
Feeding Hopper | 20 M3 Capacity with Grizzle feeder of 1200 mm x 2500 size will be provided along with the plant. The Hopper is M. S. Fabricated type with 4 Nos. supporting legs. |
Screening Arrangement | The Crushing plant will be provided with one Vibrating Screen of 15’x5’ – 4 deck. |
Conveyors | In our design, we have planned to supply complete Conveyor System Channel and Angle type construction. The supports of the Conveyor will be legs. All Conveyors are 800 mm & 500 mm belt width and the belts are endless type with 315/3 quality, 3 mm top, 1.5mm bottom & M – 24 grade of covering. In our layout planning, we have considered to supply total conveyors of 45 mtr. long in 2 sec. of 800 mm wide & 500 mm wide 95 mtr. long in 6 sec. |
Motors, Starter & Main switch | We will provide the following electric motors Required for the plant operation. All the motors are TEFC cage type 1440 rpm. |
For Primary Crusher 36”X28” | 100 HP 1 No. |
For Secondary Crusher 48”x8” | 60 HP 3 No |
For Vibrating Screen 15’x5’ | 40 HP. 1 No. |
Conveyors total (5 HPx6Nos. + 20 HPx2 Nos.) | 70 HP 1 Set |
For Feeder | 20 HP 1 No Total-410 HP |
POWER CONSUMPTION= | CONNECTED LOAD ( 410 HP ) x 0.76 ( KW ) x ACTUAL CONSUMPTION ( 0.6 ) ———————————————————————————————— 150 TONS x 0.85 ( PLANT EFFICIENC) = 1.70 KW/ TON |
Connecting Cable | We will provide you all connecting cables required for the plant. |
Connected Load | Considering provision for any additional load of 50 H.P. the total power required will be 450 HP. |
Civil Mounted <40MM Single Stage 15TPH
Standard Offer
Percentage of out put products with a possibility of variation of 5 to 10% as per requirement | - 40 + 20 mm = 25 % - 20 + 10 mm = 35 % - 10 + 5 mm = 25 % - 5 + 0 mm = 15% (The percentage may be change according to site & material condition ) |
Primary Crusher | 16” x 10” Heavy duty single Toggle Jaw Crusher – 1 No. |
Screening Arrangement | The Crushing plant will be provided with one Vibrating Screen of 8’ x 4’ size in 4 deck. The decks of the Vibrating Screen has been arranged as follows : - 1st deck – 40 mm. 2nd deck – 20 mm. 3rd deck – 10 mm. 4th deck – 5 mm. |
Conveyors | In our design we have planned to supply complete Conveyor System Channel and Angle type construction. The supports of the Conveyor will be legs. All Conveyor considered are 350 mm belt width and the belts are endless type with 315/3 quality, 3mm top, 1.5mm bottom & M – 24 grade of covering. In our layout planning we have considered to supply total conveyors of 350 mm wide 60 mtr. long in 6 sec. |
Feeding Hopper | We will provide one M.S. hopper of 7 Cu. Mtr. capacity with a suitable feeder. |
Motors, Starter & Main switch | We will provide the following electric motors Required for the plant operation. All the motors are TEFC cage type 1440 rpm. |
For Primary Crusher 16” x 10” | 30 HP. 1 No. |
For Vibrating Screen 8’ x 4’ - 4 Deck | 10 HP. 1 No. |
Conveyors total (3 HP. X 4 Nos. + 5 HP. x 2 Nos.) | 22 HP 1 Set |
Feeder 500 x 1000 | 5 HP 1 No. |
Connecting Cable | We have to procure all connecting cables required for the plant. We will provide you only specification and other details of required cable. |
Connected Load | Considering provision for any additional load of 8 HP the total power requirement of the plant will be 75 HP. |
Supervision of erection & Commissioning | We will do the supervision of erection and commissioning of the plant. The lifting equipment, boarding and lodging expenses of our supervisor will be in your account only. Doing all Civil foundation will be in your scope of supply and responsibility. Construction of ramp road, retaining wall, is under your scope of supply. Skilled and unskilled labour required is in your scope. |
Civil Mounted <40MM Single Stage 20TPH
Standard Offer
Percentage of out put products with a possibility of variation of 5 to 10% as per requirement | - 40 + 20 mm = 25 % - 20 + 10 mm = 35 % - 10 + 5 mm = 25 % - 5 + 0 mm = 15% (The percentage may be change according to site & material condition ) |
Primary Crusher | 20” x 10” Heavy duty single Toggle Jaw Crusher – 1 No. |
Screening Arrangement | The Crushing plant will be provided with one Vibrating Screen of 8’ x 4’ size in 4 deck. The decks of the Vibrating Screen has been arranged as follows : - 1st deck – 40 mm. 2nd deck – 20 mm. 3rd deck – 10 mm. 4th deck – 5 mm. |
Conveyors | In our design we have planned to supply complete Conveyor System Channel and Angle type construction. The supports of the Conveyor will be legs. All Conveyor considered are 350 mm belt width and the belts are endless type with 315/3 quality, 3mm top, 1.5mm bottom & M – 24 grade of covering. In our layout planning we have considered to supply total conveyors of 350 mm wide 60 mtr. long in 6 sec. |
Feeding Hopper | We will provide one M.S. hopper of 7 Cu. Mtr. capacity with a suitable feeder. |
Motors, Starter & Main switch | We will provide the following electric motors Required for the plant operation. All the motors are TEFC cage type 1440 rpm. |
For Primary Crusher 20” x 10” | 40 HP. 1 No. |
For Vibrating Screen 8’ x 4’ - 4 Deck | 10 HP. 1 No. |
Conveyors total (3 HP. X 4 Nos. + 5 HP. x 2 Nos.) | 22 HP 1 Set |
Feeder 500 x 1000 | 5 HP 1 No. |
Connecting Cable | We will provide you all connecting cables required for the plant. We will provide you only specification and other details of required cable. |
Connected Load | Considering provision for any additional load of 3 HP the total power requirement of the plant will be 80 HP. |
Supervision of erection & Commissioning | We will do the supervision of erection and |
Civil Mounted <40MM Three Stage 350TPH
Standard Offer
Civil Mounted <40MM Two Stage 250TPH JAW JAW
Standard Offer
Percentage of out put products with a possibility of variation of 5 to 10% as per requirement | 60 + 0 mm = 80 % - 6 + 0 mm = 20% (The percentage may be change according to site & material condition ) |
Primary Crusher | 42”X32” Heavy duty single Toggle Jaw Crusher – 1 No. |
Secondary Crusher | 48”x12 ” Heavy duty single Toggle Jaw Crusher -3 Nos. |
Feeding Hopper | 20 M3 Capacity with Grizzle feeder of 1200 mm x 3000 size will be provided along with the plant. The Hopper is M. S. Fabricated type with 4 Nos. supporting legs. |
Screening Arrangement | The Crushing plant will be provided with one Vibrating Screen of 20’x5’ – 2 deck. |
Conveyors | In our design, we have planned to supply complete Conveyor System Channel and Angle type construction. The supports of the Conveyor will be legs. All Conveyors are 1000 mm & 500 mm belt width and the belts are endless type with 315/3 quality, 3 mm top, 1.5mm bottom & M – 24 grade of covering. In our layout planning, we have considered to supply total conveyors of 60 mtr. long in 3 sec. of 1000 mm wide & 600 mm wide 40 mtr. long in 2 sec. |
Motors, Starter & Main switch | We will provide the following electric motors Required for the plant operation. All the motors are TEFC cage type 1440 rpm. |
For Primary Crusher 42”X32” | 125 HP 1 No. |
For Secondary Crusher 48”x12” | 75 HP 3 No |
For Vibrating Screen 20’x5’ | 40 HP. 1 No. |
Conveyors total (10 HPx2Nos. + 20 HPx3 Nos.) | 80 HP 1 Set |
For Feeder | 30 HP. 1 No. Total - 500 HP |
POWER CONSUMPTION= | CONNECTED LOAD (500 HP) x 0.76 (KW) x ACTUAL CONSUMPTION (0.6 ) ———————————————————————————————— 250 TONS x 0.85 (PLANT EFFICIENCY) = 1.42 KW/ TON |
Connecting Cable | We will provide you all connecting cables required for the plant. |
Connected Load | Considering provision for any additional load of 25 H.P. the total power required will be 450 HP. |
Supervision of Erection & Commissioning | We will do the supervision of erection and commissioning of the plant and for the same we will charged @ 5 % extra. Our responsibility will be to supervise the erection and commissioning of the plant only and we will be also responsible for trial production of the plant. However providing compacted leveled surface, construction of ramp road, providing skilled labour, lifting equipment, welding transformer and welding gas set, other tools and tackles required for erection and commissioning of the plant will be under your scope of supply and responsibility. |
Civil Mounted <40MM Two Stage 25TPH
Standard Offer
Percentage of out put products with a possibility of variation of 5 to 10% as per requirement | - 40 + 20 mm = 25 % - 20 + 10 mm = 35 % - 10 + 5 mm = 25 % - 5 + 0 mm = 15% (The percentage may be change according to site & material condition ) |
Primary Crusher | 20” x 12” Heavy duty single Toggle Jaw Crusher – 1 No. |
Secondary Crusher | 24” x 6” Heavy duty single Toggle Jaw Crusher – 1 No. |
Feeding Hopper | 7 M3 Capacity with Grizzle feeder of 600 mm x 1200 size will be provided along with the plant.The Hopper is M. S. Fabricated typewith 4 Nos. supporting legs. |
Screening Arrangement | The Crushing plant will be provided with one Vibrating Screen of 8’ x 4’ - 4 deck. |
Conveyors | In our design, we have planned to supply complete Conveyor System Channel and Angle type construction. The supports of the Conveyor will be legs. All Conveyor considered are 350 mm belt width and the belts are endless type with 315/3 quality, 3mm top, 1.5mm bottom & M – 24 grade of covering. In our layout planning, we have considered to supply total conveyors of 30 mtr. long in 2 sec. of 500 mm wide & 350 mm wide 75 mtr. long in 5 sec. |
Motors, Starter & Main switch | We will provide the following electric motors Required for the plant operation. All the motors are TEFC cage type 1440 rpm. |
For Primary Crusher 20” x 12” | 40 HP. 1 No. |
For Secondary Crusher 24” x 6” | 40 HP. 1 No. |
For Vibrating Screen 8’ x 4’ | 15 HP. 1 No. |
Conveyors total (3 HP. X 5 Nos. + 5 HP. x 2 Nos.) | 35 HP 1 Set |
Feeder | 10 HP 1 No. |
Connecting Cable | We will provide you all connecting cables required for the plant. We will provide you only specification and other details of required cable. |
Connected Load | We will do the supervision of erection and commissioning of the plant. The lifting equipment, boarding and lodging expenses of our supervisor will be in your account only. Doing all Civil foundation will be in your scope of supply and responsibility. Construction of ramp road, retaining wall, is under your scope of supply. Skilled and unskilled labour required is in your scope. |
Supervision of erection & Commissioning | We will do the supervision of erection and commissioning of the plant. The lifting equipment, boarding and lodging expenses of our supervisor will be in your account only. Doing all Civil foundation will be in your scope of supply and responsibility. Construction of ramp road, retaining wall, is under your scope of supply. Skilled and unskilled labour required is in your scope. |
Questions about the crusher
How do I determine the appropriate crushing plant capacity for my needs?
What is the recommended feed size for the crushing plant?
How do I choose between a single-stage and a two-stage crushing setup?
What output size can I expect from this crushing plant?
Will wet, sticky materials impact the performance of the crushing plant?
What type of foundation is required for the crushing plant?
How do I decide the number of crushing stages required for my application?
What alternative crushing technologies should I consider besides Roll Crushers?
How does the plant handle varying feed sizes and materials?
What maintenance considerations are there for this type of crushing plant?