During urban development and construction, have you ever been troubled by the challenge of managing construction waste? It not only occupies vast amounts of land but also causes environmental pollution. However, with technological advancements, the emergence of Mobile Crushers now allows us to successfully transform this “waste” into “renewable resources.” Let’s explore this remarkable transformation process in detail.
I.Why Should We Deal With Construction Waste?
Three Major Hazards of Untreated Construction Waste
Environmental Damage: Random stacking leads to soil compaction, and harmful substances can seep into the ground, polluting water sources.
Safety Risks: Excessive accumulation can easily cause collapses, and combustible materials like wood and plastic can pose fire hazards.
Economic Burden: Landfilling consumes precious land resources, and transportation and disposal costs can also be a headache for you.
The Recycling Value of Construction Waste
In fact, with proper handling, the resources hidden within construction waste can be given a new lease of life.
Aggregate Recycling: By crushing and screening concrete blocks, bricks and stones there can be produced a compound product for manufacture by means of recycled aggregate for replacement of natural sand and gravel, which can be used for building constructions etc.
Metal recycling: By separating and recycling re-inforcement, wire and other materials, they can be produced for the steel industry for manufacture of building steel and other metal products.
Cost saving: By reducing the purchase of natural sands and gravel, reducing the base costs of raw materials, avoiding landfill and saving in transport and tipping.
II. Why Mobile Crushers Are Your Best Choice
Mobile Crusher Definition
Mobile Crusher means a portable integrated machine that can be easily transported from one site to execute the procedures feed – crush – screen – convey. It will also not be necessary to create a site for working purposes as it is possible for this equipment to travel automatically according to the area of work required. The construction of the Mobile Crusher is specially designed to attack the waste from trade, especially that which cannot be moved from site.
Components of Mobile Crusher and Their Functions:
The efficient operation of mobile crushing equipment depends on the coordinated cooperation of five core systems, none of which can be missing:
Feeding Systems: This machine supplies a uniform quantity of construction waste to the Crusher, so there will be no clogging of machinery due to improper feeding.
Crushing System: This is the heart of the system, or the essential part, which takes the large pieces of material in and breaks them down into smaller pieces.
Screening System: This machine takes the crushed material and separates it into various classes. Conveying System: A machine is supplied which carries the aggregate to the place where you want it.
Electric System: This machine supplies power to the complete system, and in regards to the manner of power used, this can be varied in accordance with your own site, depending upon their requirements.
Power System: The system for providing power for the whole equipment. For this diesel or electric power can be chosen according to conditions of the worksite, whereby flexible adaptation to the different cases is available.
How Does A Mobile Crusher Work?
The mobile crushing station is highly efficient and seamless throughout the entire process, transforming construction waste into valuable recycled resources right on-site.
Feeding: Construction waste is fed into the feeding system, where a vibrating feeder evenly transports it to the crushing system.
Iron removal: A de-ironing device removes metal impurities such as steel bars and wire to ensure aggregate purity.
Crushing: Devices are activated based on material hardness to reduce bulky material to a pre-set particle size.
Screening: The material enters the screening system, where recycled aggregate of varying sizes is separated according to desired particle size.
Conveying: Qualified aggregate is transported by the conveying system to a designated location for centralized impurity treatment.
Main types of Mobile Crushers (select according to “demand”)
| Classification Dimension | Type | Processing Function | Applicable Scenarios | Core Advantages |
| By Mobility | Wheeled Mobile Crusher | Tire Movement “Feeding-Crushing-Screening” integrated | Flat terrain (Urban demolition sites, industrial parks) | Fast movement speed, flexible transitions, convenient for frequent changes of location |
| Tracked Mobile Crusher | Track Movement “Feeding-Crushing-Screening” integrated | Rough terrain (Mountainous regions, hilly areas, muddy sites) | Large contact area of the ground, good grip, favourable to stable operations in difficult terrain. | |
| By Processing Function | Jaw Mobile Crusher | Primary Crushing (Reduction of large materials to intermediate size) | Coarse grinding of large concrete, granite in the field of urban demolition or rough country. | Wheeled for fast transfer. Tracked for adaptation to difficult terrain. Great igneous force is available for grinding hard materials. |
| Impact Mobile Crusher | Medium & Fine Crushing (Further crushing after primary stage) | Medium and fine grinding of concrete blocks, limestone in urban demolition, industrial park, high quality recycled aggregate is produced. | Resists clogging from impurities; produces well-shaped end products; mobile version allows quick setup and production. | |
| Cone Mobile Crusher | Fine Crushing (Precise crushing of high-hardness materials) | Secondary/tertiary crushing of granite and basalt in mountain mining areas. | Ideal for high-hardness materials; can process mixed C&D waste + tailings; suitable for complex terrain. | |
| VSI Mobile Crusher | Sand and Gravel Aggregate Sand Making | High-standard aggregate production, suitable for motorway and road construction. | Complies with premium sand specifications for infrastructure projects, with convenient relocation. | |
| Hammer Mobile Crusher | Single-pass processing (direct crushing to target particle size) | Direct crushing of demolition waste, shale in the muddy and mountainous demolition sites. | Capable of dealing with materials containing reinforcement, thus cost per ton reduced, highly mobile. |
Advantages of Mobile Crushers
On-site operation: The machine is delivered directly to the customer’s site for waste crushing, eliminating the hassle of transportation.
Always Ready to Move: When one job is finished the machine goes without loss of time to the next job yielding no expense of installation of any kind and thus gaining a great moral boost in efficiency.
Quick Installation and Ultimate Efficiency: As soon as the machine is installed operations begin on the job yielding the benefit of the omission of the expense and time requirements of complicated fixed production lines.
Instant Producers, Instant Returns: Aggregates of various specifications are produced higher up the production line immediately available for immediate use on the spot or sale.
High Adaptability: The machine is highly adaptable even with reduced area constraints in urban demolition work.
IV. The Complete Process of “Turning Waste into Treasure”
The whole process is simple and clear: Feeding → Crushing (Iron removal simultaneous) → Screening → Multiple finished products which makes it easy to realize the utilization of resources.
Process Description
Screening and Iron removal: We first separate the impurities like soil and wood chips, then by an iron remover we remove the steel reinforcement to ensure the purity of the aggregate.
Core Crushing Process: Select crushing methods based on finished product requirements. For instance, when different aggregate sizes are needed, employ a coarse crushing (Jaw Crusher) + fine crushing (Cone Crusher) combination.
Mobile Impact Crushers are commonly used equipment for processing construction waste, particularly suited for crushing concrete and bricks.
Multiple Screening System: Gives you through accurate screening various specifications of the recycled products.
V. The value and application of recycled aggregate (after recycling construction waste)
Application Areas
Infrastructure Jobs: Most suited to road base courses, site backfilling and other engineering jobs.
Municipal Landscaping: To make permeable bricks for the park paths, mixed with soil as a planting substrate for green belt or filling landscape planters and slopes.
Filling Engineering: Used for site levelling (as raising ground levels in industrial park), or mine backfilling, (decreasing the risk of good areas).
Example of the Money Values
Taking the processing of 100,000 tons of building waste as an example, you will get:
Cost Saving: An approx. saving of $210,000 on outside transport and abt. $110,000 on the tipping fees.
Revenue Making: An approx. earning from the sale of the recycled aggregates of $170,000.
Return on the Money Invested: The equipment investment can usually be recovered in a period of 6 – 12 months.
VI. Real Case Studies Case
Case1: Urban high-rise building demolition
Background and Main Difficulties
Location: Demolition of an old industrial building in a certain city
Main Difficulties: Lack of space: The site is located next to an important road and shopping district,
Short time: Demolition and clearance must be completed in 90 days;
High pressure on environmental safety and operational safety: Dust and noise must be kept under close control, high cost of transport concerning construction waste, short time allowed for access.
The solution and the implementation process
Tailored solutions：
Configuration of equipment used: 1 wheel-mounted mobile impact type crushing machine and 1 screening equipment wheel-mounted mobile.
Implementation Process:
Fast Delivery: The equipment arrives on-site within 48 hours, and installation, commissioning, and trial operation are completed within 12 hours.
On-site Processing: Reinforced concrete blocks removed on-site are fed directly into the crushing equipment. An iron remover is installed at the Impact Crusher feed port, and the crushed aggregate is fed into a screening unit.
Fine Screening: After screening, the recycled aggregate is classified into three grades (0-5 mm, 5-10 mm, and 10-31.5 mm).
Project Results:
Economic Benefit: Saved over $200,000 in waste hauling and landfill fees.
Recovered aggregate generated approximately $120,000 in revenue.
Time: All demolition work and disposal of waste was completed in only 85 days, 5 days before the period stated.
Environmental protection and safety: Closed-loop management of dust and noise was continued through the process, receiving great recognition by the client and the town administration.
Case 2: Large Bridge Demolition and Concrete Waste Recycling Project
Location: Renovation Project of an Old Highway Bridge
Core Challenges:
Hardened Material: The old bridge piers and box girders were constructed of C50 high-grade reinforced concrete with a dense structure;
High Quality: The recycled aggregate used in the subgrade of the new bridge required a uniform particle shape and low flake content;
High Efficiency: 80,000 tons of concrete were processed within six months.
Solution and Implementation Process
Recommended: A three-stage mobile crushing solution consisting of a Jaw Crusher, Impact Crusher, and VSI Crusher
Equipment Selection and Configuration:
1 crawler-mounted mobile crushing station with Jaw Crusher and Impact Crusher (for primary and secondary crushing);
1 crawler-mounted mobile crushing station with VSI Crusher (for sand making, shaping, and fine crushing);
Equipped with a mobile screening station and iron removal system.
Four-Step Efficient Processing Process:
Step 1: Pretreatment + Primary Iron Removal
During feeding, a powerful iron remover above the feeder removes surface steel and wire.
Step 2: Two-stage Crushing + sSecondary Iron Removal
A Jaw Crusher coarsely crushes the material to less than 180mm; a secondary iron remover removes metal from the material; an Impact Crusher performs fine crushing to less than 40mm and shapes the material.
Step 3: Screening + Fine Sand Making
Screening and diversion: Aggregates ≥31.5mm are returned to the Impact Crusher, 20-31.5mm/10-20mm are stored as finished products, and 0-5mm sand is stored;
Aggregates below 40mm enter the VSI Crusher for fine sand making and shaping;
Final screening produces 0-5mm machine-made sand, and a tertiary iron removal process removes fine iron chips.
The recycled aggregate produced fully meets the material requirements of the highway.
Achieving an hourly processing capacity of 180 tons and a processing capacity of 80,000 tons in 5.5 months.
The waste recycling rate reaches 98%.
FAQ
Q1: What is the processing capacity of your Mobile Crusher? Can it meet my project needs?
A: There are many Mobile Crusher models, with hourly processing capacities ranging from tens to hundreds of tons. We can recommend the most suitable model based on your project scale, waste type, and expected output to maximize investment efficiency.
Q2: What are the site requirements for your Mobile Crusher for sand production?
A: The requirements are very flexible. As long as there is sufficient space for the equipment (including the feed area and finished material pile), and safe access to and from the equipment, it is sufficient. Even on relatively cramped urban demolition sites, crawler-type Mobile Crushers can adapt well.
Q3:Is the quality of recycled aggregates produced by Mobile Crushers stable and how is their market acceptance?
A: Through the appropriate selection and process design of the Mobile Crusher, the recycled aggregate produced fully meets relevant industry standards. Recycled aggregate is widely used in roadbeds, brickmaking, and other fields, and market demand is strong, so sales are not a problem.
