practical guide for engineers and procurement teams. This article explains basalt crushing for roadworks, machine principles, key parameters, tested data and field cases. It helps you select, size and operate a plant with confidence.
Basalt is a dense, volcanic rock. It offers high compressive strength and good abrasion resistance. These qualities make basalt ideal for base, subbase, and asphalt aggregates. Engineers prefer basalt where durability and skid resistance are required. Basalt grading normally ranges from 0–50 mm for base layers. This fits typical road standards in the Philippines and ASEAN markets.
Road aggregate plants commonly use three stages. First, a jaw crusher for primary reduction. Next, a cone crusher (or gyratory) for secondary sizing. Finally, a VSI or impactor for shaping and fine grading. Feed control and screening are critical at each stage. This staged approach balances throughput, product quality and wear.
Jaw crusher: compressive crushing by moving and stationary jaws. Key parameters: gape, feed opening, maximum feed size, throughput (tph). Design rule: max feed ≈ 80% of jaw gape.
Cone crusher: conical mantle oscillates inside a concave shell. Crushing happens between mantle and concave. Important parameters: CSS (Closed Side Setting), OSS (Open Side Setting), eccentric throw, rotor speed, crushing ratio, power matching and chamber profile. Typical CSS range for secondary/tertiary cones: 6–75 mm depending on desired product. A small CSS gives finer product and lower capacity; a larger CSS raises capacity and coarser output.
VSI crusher: high-speed rotor accelerates rock, causing rock-on-rock crushing. It improves particle shape. Useful for final sand and shape-critical road layers. VSI selection depends on rotor speed, feed gradation and liner material.
Below is a compact plant specification sheet for a 150–300 tph basalt road aggregate line.
| Item | Parameter | Range |
|---|---|---|
| Jaw crusher | Feed size / Capacity | 0–700 mm / 50–300 tph |
| Cone crusher | CSS / RPM / Motor | 6–30 mm / 600–900 rpm / 160–315 kW |
| VSI | Product size / Rotor speed | 0–5 mm / 1200–1500 rpm |
Capacity depends on feed gradation, moisture and rock strength. For basalt with uniaxial compressive strength around 100–300 MPa, expect conservative capacity reductions versus limestone. Manufacturers quote open-circuit capacities; closed-circuit yields more stable gradings. Typical jaw sizes and capacities are given in industry tables. Use vendor curves for final sizing.
Measured energy use varies by stage. Primary crushing often consumes 10–25 kWh per tonne for very hard rock. Secondary cone crushing adds 5–15 kWh/t. VSI energy use is higher per tonne for fine sand. Mean time between major repairs (MTBM) depends on abrasion, liners and lubrication. Good practice: scheduled liner checks every 500–1500 operating hours. Lube systems and condition monitoring extend uptime. Field studies show that proper matching of motor power and CSS reduces overloads and lowers wear.
Record feed gradation hourly. Log CSS and rotor speed. Track tonnage vs fuel and power. Note moisture and fines content. Inspect liners weekly. Keep a daily register of blockages and downtime minutes. These records enable accurate wear and capacity forecasting. They also reduce unplanned stops.
Project brief: 180 tph plant for provincial road base. Feed: blasted basalt boulders, 0–800 mm. Climate: tropical, high humidity and seasonal heavy rains. Equipment supplied: 900×1200 jaw crusher, 150 kW cone crusher with 12–30 mm CSS range, 2-stage vibrating screens and a VSI for shaping. Design decisions: coarse primary to protect cone liners, staged screening to reduce recirculating load, covered conveyors for rainy season. Results: stable 180 tph throughput, final base gradation 0–50 mm with 90% passing 25 mm. Client feedback: easy commissioning, lower dust after covered conveyors, predictable maintenance cycle. .
Project brief: 120 tph mobile plant for shoulder works and patching. Feed: quarried basalt, 0–500 mm. Equipment: mobile jaw 700×900, medium cone, double-deck screen, portable batching. Design notes: focus on mobility, quick set-up, and material traceability. Outcomes: reduced transport costs, 95% on-spec material, maintenance interval extended to 1200 hours for cone liners due to optimized CSS control. User comment: installation was on schedule; production stability during wet season improved.
Step 1: Determine annual tonnage and peak hourly demand. Step 2: Analyze feed maximum size and rock strength. Step 3: Choose primary crusher gape to accept 80% of max feed. Step 4: Select cone/VSI to meet final gradation. Step 5: Add 15–25% redundancy for wear and moisture. Each step requires measurement and vendor verification. Use vendor curves and a conservative safety factor.
Plan foundations for heavy crushers. Provide dust suppression and crusher covers in wet tropics. Match motor rating to crushing torque with 10–20% safety margin. Implement vibration and oil-temperature monitoring. Keep critical spares: liners, mantle, concave, wear plates, V-belts, and lube filters. Train local staff on CSS adjustments and emergency stops. This reduces downtime and lowers lifecycle cost.
A1: Choose CSS that yields required gradation. For coarse base, 20–40 mm CSS often works. For finer base layers, reduce CSS to 6–15 mm. Test with a pilot run and adjust. Small CSS lowers capacity; plan for that.
A2: Use harder liner materials, reduce circulating load, control feed top size, and optimize CSS. Consider a staged crushing with protective sacrificial liners. Regular kerf inspections prevent sudden failures.
A3: Add a VSI or tertiary impactor. Control feed gradation to the VSI. Maintain rotor speed and replace worn blowbars promptly. Good screening reduces over-crushing and improves shape. Conduct routine particle shape tests.
Basalt is an excellent road material. Select crushers based on feed size, target gradation and operation tempo. Prioritize robust components, proper motor matching and a monitoring plan. Field records and test runs validate capacity and wear. For turnkey supply and local service, consider vendors with regional experience and spare-parts presence. SBM can provide tailored lines, on-site commissioning and training to ensure uptime and specification compliance.
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