An aggregate crusher is a powerful machine designed to break down large rocks, gravel, or recycled concrete into smaller, usable fragments. Serving as a versatile workhorse in both the mining and construction industries, it transforms raw materials into consistently sized aggregate essential for building foundations, roads, and concrete production.
What Raw Materials Can Be Crushed into Aggregate?
High-quality construction aggregate can be produced from a variety of raw materials, both virgin and recycled. Understanding the source materials helps maximize resource efficiency and project sustainability. Here shows some key raw materials for aggregate production:
Virgin Stone & Rock
Examples: Limestone, granite, basalt, sandstone, gravel.
Characteristics: Mined directly from quarries, these hard, dense materials are the traditional source for high-specification concrete and asphalt aggregates.
Recycled Concrete
Primary Source: Demolished structures, pavements, foundations, and other concrete waste.
Value: The most common and valuable recycled material for aggregate production, offering significant environmental benefits by diverting waste from landfills.
Recycled Masonry & Bricks
Examples: Crushed bricks, clay tiles, concrete blocks, and other masonry debris from demolition sites.
Application: Produces aggregates suitable for sub-base layers, drainage applications, pipe bedding, and some lower-grade concrete mixes.
Recycled Asphalt Pavement (RAP)
Source: Reclaimed asphalt from road milling and resurfacing projects.
Use: Primarily reprocessed into new asphalt mixes or used as a stable aggregate base material.
Quarry By-Products
Examples: Sand, gravel fines, and lower-grade rock fractions previously considered waste material during primary quarrying operations.
Benefit: Transforms quarry waste streams into usable aggregate products like fill or bedding material.
Utilizing waste materials like concrete rubble and crushed bricks not only conserves natural resources but also reduces landfill burden, making recycled aggregates a cost-effective and environmentally responsible choice for modern construction.
Essential Aggregate Crushers: Matching Equipment to Your Production Needs
Producing high-quality aggregate requires the right combination of crushing equipment, chosen based on the raw material and desired end product. Here’s an overview of the key crusher types used in aggregate production lines:
Primary Crushers for Aggregates: The First Reduction Stage
- Function: Handle the largest feed size (directly from the quarry face or demolition site). Perform the initial, coarse size reduction.
- Key Types:
Aggregate Jaw Crushers: Robust workhorses using compressive force. The jaw crusher is ideal for hard, abrasive materials (granite, basalt, recycled concrete). Produce a relatively coarse product. - Output: Coarse aggregate (e.g., for road base) or feed for secondary crushers.
Secondary Crushers for Aggregates: Refining Size & Shape
- Function: Take the output from the primary crusher and further reduce it to intermediate sizes. Focuses on producing better-shaped particles and achieving the required gradation.
- Key Types:
- Aggregate Cone Crushers: Utilize compression within a rotating mantle and concave. The cone crusher is excellent for producing well-shaped cubical aggregate from medium-hard to hard materials (limestone, granite, recycled concrete). Ideal for producing aggregate for concrete and asphalt.
- Aggregate Impact Crushers: Use high-speed impact force (hammers/blow bars hitting the material). Excellent for softer to medium-hard materials (limestone, recycled asphalt RAP, recycled concrete, brick). Produce a more cubical product than jaw crushers and are often used for both primary (softer materials) and secondary roles. Note: Our mobile impact crushers feature heavy-duty rotors for two-stage capability and superior particle shape.
- Output: Intermediate sizes ready for final screening or tertiary crushing.
Tertiary/Fine Crushers & Sand Makers: Achieving Final Specifications
- Function: Produce the final, often finer, aggregate fractions (including sand) with precise shape and gradation control.
- Key Types:
- Vertical Shaft Impactors (VSI) / Sand Makers: Utilize high-speed rotor impact and “rock-on-rock” crushing principle. Produce the highest quality, well-shaped cubical aggregate and manufactured sand, especially crucial for concrete and asphalt production. Note: Our mobile plants offer easy interchangeability (e.g., swapping an HSI for a VSI crusher module) for flexible production.
- Fine Cone Crushers: Specialized fine aggregate crushing machines configured to produce a finer product than standard secondary cones.
Aggregate Screening Equipment: Precision Sizing for Quality Control
- Function: Separate crushed aggregate into precise size fractions after primary, secondary, or tertiary crushing stages. Ensure final product meets specification requirements (e.g., ASTM/EN standards). Screening determines end-product quality and value, directly impacting concrete strength, asphalt durability, and construction compliance.
- Key Type of Aggregate Screens for Sale:
Vibrating Screens：For high-capacity sorting of crushed rock, sand, and gravel.
- Features:
- Multi-deck configurations produce 3–5 graded products simultaneously.
- Heavy-duty mesh or rubber media withstands abrasive materials.
- Variable amplitude/frequency adapts to moisture or sticky ores.
- Ideal For: Final product sizing in large aggregate screening plants.
While crushers are categorized by function (primary, secondary, tertiary), they can be deployed in stationary plants (fixed foundations, high-volume production) or mobile plants (tire or track-mounted, rapid setup/relocation).
Mobile Aggregate Crusher: Flexibility Where You Need It
Andamine provides two kinds tire-mounted crusher: four-in-one and three-in-one model. They share some common advantages and also have their own shinning points:
- Integrated Control System: Both the four-in-one and three-in-one models come with an integrated control system, allowing for one-click start-up via either a PLC touchscreen or button control. This simplifies operation and increases productivity.
- IOT Remote Monitoring System: The machines are equipped with a remote monitoring system, which tracks equipment performance in real-time. This helps reduce failure rates, ensures timely maintenance, and allows for the monitoring of the machine even in remote locations with low signal by using Wi-Fi or wired networks.
- Smart Feeding System: The mobile crushers are equipped with smart feeding systems. The feeder can be remotely controlled, and the feeding speed can be adjusted to ensure a continuous and smooth production process.
- Mobility and Stability: The tri-axle chassis design allows for easy transportation and quick relocation to different sites. The use of ski plate support enhances stability and increases ground contact, making these machines suitable for a variety of terrain conditions.
Tire-Mounted Four-in-One Crusher
This model is perfect for those requiring maximum flexibility in their crushing operations. It offers:
- Customizable Crusher Combination: You can easily change between crushers like fine jaw crushers or impact crushers, allowing for optimal processing depending on your project’s needs. It’s a versatile solution for various working conditions.
- Heavy-duty Features: The four-in-one crusher features advanced technology such as the ROSTA elastic vibration support, which ensures smoother startup and shutdown, with minimal irregular vibrations. It’s also equipped with a self-unloading iron separator, which prevents damage from iron contamination.
- Efficient Operation: This model boasts a modular design, making it easy to replace secondary crushers. Whether you need a fine jaw crusher or impact crusher, this flexibility ensures that the machine meets your requirements for different projects.
Tire-Mounted Three-in-One Crusher
The three-in-one mobile crusher is another excellent solution that combines crushing, screening, and feeding functions. This model is especially ideal for smaller-scale projects or those that require a compact machine without sacrificing performance. Its key features include:
- Heavy-duty Rotor: The impact crusher is designed with a heavy-duty rotor to handle two-stage crushing. It provides a larger crushing ratio and better product shape.
- Enhanced Durability: Features such as the buffer bed design on the main conveyor belt and double sealing on the impact crusher inlets and outlets improve durability, reduce dust emissions, and increase overall service life.
- Energy-efficient Motor: The three-in-one model comes equipped with an energy-efficient motor that reduces power consumption by up to 30%, making it more eco-friendly and cost-effective in the long run.
- Dust Control System: An integrated dust control system, including mist cannons and dust covers for conveyors, ensures that the working environment remains clean, with minimal dust and pollutant emissions, in compliance with environmental regulations.
Fixed Crushing Solutions: For Long Term Project
Custom-engineered for high-volume, permanent operations (large quarries, mega infrastructure projects).
Core Advantages:
- Tailored Design: Fully customized layouts based on raw material, capacity (500-2000 TPH+), and product specs.
- Maximized Efficiency: Optimized flow paths reduce energy waste, lowering cost/ton.
- Durability & Scale: Heavy-duty foundations support 24/7 operation with 20-30+ year lifespans.
- Integrated Systems: Seamless conveyor networks, advanced dust control, and automated sorting.
Customer Cases
250tph Mobile Crusher in the Chile
- Usage: Concrete aggregate production and sales
- Raw material: Basalt
- Capacity: 250 tons per hour
- Type: Mobile, crawler type
- Location: Chile
- Finished particle size: 0-10-20-40mm
120tph Aggregate Crushing Plant in Zanzibar
- Usage: Produce aggregate to secure their own concrete batching plant’s material supply chain
- Raw material: Limestone
- Capacity: 100-120 tons per hour
- Type: Stationary
- Location: Zanzibar
- Finished particle size: 0-5, 5-10, 10-20, and 20-30mm
- Equipment configuration: Vibrating feeder, jaw crusher, impact crusher, and vibrating screen
350tph Concrete Aggregate Crushing Plant for Malaysia
- Usage: Production of sand and gravel aggregate
- Raw material: River pebbles
- Capacity: 350 tons per hour
- Type: Stationary
- Location: Malaysia
- Finished particle size: 0-7-13-19-30mm
- Equipment configuration: Jaw Crusher, single-cylinder cone crusher, VSI crusher
Versatile Applications Across Industries
Aggregate crushers are indispensable across sectors where raw material processing defines success. Our engineered solutions deliver precision-crushed aggregates for:
Quarry OperationsProduce consistent, high-volume aggregates (sand, gravel, crushed stone) for construction markets. Our mobile units excel with rapid site transitions and minimal setup downtime.
Mining & Mineral ProcessingCrush ores, limestone, or granite into specified sizes for further processing or direct use. Remote monitoring ensures uninterrupted production in remote locations.
Construction & Demolition RecyclingTransform concrete, asphalt, and masonry waste into reusable aggregates—slashing landfill costs and raw material expenses. Integrated metal removal protects crushers from rebar damage.
Road & Infrastructure ConstructionCreate stable base layers (sub-base, base course) and asphalt/concrete aggregates with precise gradation. Mobility allows on-site crushing, reducing hauling costs by 60%.
Concrete & Asphalt Plant FeedstockGenerate uniformly sized aggregates critical for batching quality concrete or hot-mix asphalt. Smart feeding systems maintain optimal production flow.
Landscaping & Erosion ControlProduce decorative stone or riprap for drainage, retaining walls, and shoreline stabilization. Dust suppression tech keeps sites eco-compliant.
Aggregate Crusher Selection Guide: Key Factors to Consider
Choosing the right crusher machine requires balancing material properties, output goals, and operational constraints. Below are the decisive parameters for optimal performance and ROI:
Material Characteristics: The Primary Consideration
Hardness & Abrasiveness (e.g., Granite vs. Limestone):
High-abrasion rock (e.g., quartzite): Use jaw crushers (for primary) + cone crushers (secondary) with reinforced manganese steel liners.
Medium/low-abrasion rock (e.g., limestone): Impact crushers excel for cost efficiency and particle shaping.
Moisture & Clay Content:
Sticky, high-moisture material (>10% clay): Prioritize impact crushers or hybrid jaw-impact units with anti-clogging designs. Avoid standard cone crushers.
Feed Size & Gradation:
Oversized lumps (>1 m): Require large-jaw crushers (e.g., HDX125 with 900 mm feed opening).
Variable-sized feed: Grizzly pre-screens or vibrating feeders ensure steady flow to prevent jamming.
Production Capacity & Project Scale
Small Sites (<200 TPH): Mobile jaw/impact combos (e.g., 3-in-1 units) minimize footprint while handling 50–200 TPH. Large Quarries (>500 TPH): Stationary jaw-cone-screen circuits (e.g., HDX125 jaw + multi-cylinder cone) sustain 280–750 TPH.
Variable Demand: Modular plants allow adding/removing sections (e.g., screen or secondary crusher).
Finished Aggregate Specifications
Coarse Aggregates (Road Base):
Target particle shape: Cubical (high fracture ratio).
Preferred crushers: Cone crushers (for uniform 20–50 mm) or vertical shaft impactors (for precise shaping).
Fine Aggregates (Concrete Sand):
Avoid over-crushing: Short-head cone crushers or hybrid impact-sand makers reduce sub-5 mm “fines” waste.
Recycled Materials:
Include magnetic separators and wind sifters to remove rebar/contaminants.
Site Mobility & Space Constraints
Tire-mounted mobile crushers: Tri-axle chassis + sledger support enable quick relocation ≤30 mins.
Compact 3-in-1 units integrate feeding, crushing, screening in ≤15 m length.
Fixed Plants (Large Quarries):
Custom stationary designs (e.g., multi-stage jaw-cone-VSI) maximize longevity but need civil foundations.
Project Location & Environmental Factors
Diesel-electric hybrid drives reduce fuel dependency.
IoT remote monitoring (2G/3G/4G/WiFi) enables low-bandwidth diagnostics.
Dust/Sensitive Zones:
Closed-loop water spray systems or negative-pressure dust collectors comply with PM10/2.5 standards.
Permitting Challenges:
Noise-dampened enclosures (<75 dB) and low-vibration designs (e.g., ROSTA mounts) ease approvals.
Aggregate Crusher Industry Outlook
Market Demand Dynamics
The global crushing equipment market will reach $9.18 billion by 2037, growing at 7.4% annually. Urbanization drives this trend, with urban populations increasing 1.68% yearly and mega-projects like China’s Belt and Road accelerating infrastructure needs. The U.S. alone consumes 2.8 billion tons of aggregates annually, reflecting massive global demand.
Recycling is transforming the industry: mobile crushers enable 60% CO₂ reduction by processing demolition waste on-site, as demonstrated in Shenzhen’s 2-million-ton recycling project. The EU now mandates 70% construction waste recycling by 2030, making crushers essential for cost-efficient compliance.
Technology Evolution
Hybrid and electric crushers reduce energy costs by 30%, while IoT-enabled predictive maintenance cuts downtime 25% through real-time alerts. AI optimization systems automatically adjust crusher settings, boosting yield by 15%. Modular designs now allow machinery reconfiguration in under 1 hour, and compact mobile units occupy 40% less space – critical for urban job sites.
ESG Integration
ESG (Environmental, Social, and Governance) refers to sustainability and ethical practices in business operations, increasingly influencing construction and equipment choices. In the aggregate crusher industry, localized recycling with crushers slashes transport-related emissions by 60%. Leading projects now repurpose industrial byproducts like slag or tunnel muck to earn LEED certification. Mobile units minimize ecological disruption by operating within existing facilities, processing up to 350 tons hourly without new land use. Remote operation via IoT also enhances worker safety by reducing on-site exposure.
Aggregate Crusher Provide Raw Materials for Whom?
In most construction and materials production scenarios, an aggregate crusher is not used in isolation. Instead, it works in combination with other systems that rely on crushed materials to function efficiently. Whether producing concrete, asphalt, or dry mortar, these downstream plants depend on stable, high-quality aggregate supply — and that’s where crushing equipment plays a crucial role. The integration ensures optimized material flow, better cost control, and consistent end-product quality.
Concrete Batching Plant
Concrete production requires a reliable supply of sand, gravel, and crushed stone — all of which come directly from aggregate crushers. When paired with a concrete batching plant, the system supports on-site concrete manufacturing, improving logistics and reducing reliance on external suppliers. This setup ensures consistent particle sizes for quality concrete and cuts transportation costs.
Get A Quote
Asphalt Mixing Plant
Asphalt requires well-graded aggregates to bond properly with bitumen. With a crusher working directly with the asphalt mixing unit, contractors can produce road base materials tailored to local standards. This is particularly important for remote or rural road projects where raw material access is limited. The result: reduced material waste, better quality control, and cost savings on procurement.
Get A Quote
Dry Mix Mortar Plant
Mortar formulations rely on fine, uniform aggregates like crushed limestone, quartz, or basalt. Crushers feed directly into dry mix plants, allowing producers to manage their own sand supply. This improves consistency, reduces quality issues, and enables precise control over final mortar performance.
Get A Quote
Why Integrate Crushing and Production?
By combining crushing machines with production plants, companies gain speed, autonomy, and savings. Whether you’re building infrastructure, paving roads, or manufacturing pre-mixed materials, controlling your own aggregate supply eliminates delays and cost overruns. We offer complete systems and customized solutions for your project type, from aggregate crushing to mixing and batching. When properly planned, an integrated setup using aggregate crushers as the raw material foundation unlocks better ROI, higher efficiency, and smoother operations for any downstream application.
Why Partner with ANDAMINE: Engineering Excellence for Demanding Operations
ANDAMINE designs aggregate crushers that thrive where others fail. Our solutions withstand nature’s extremes while delivering uncompromising productivity.
Extreme Environment Adaptation
In tropical environments like Southeast Asian quarries, we combat relentless humidity with corrosion-resistant stainless steel screening meshes. This proprietary adaptation doubles component lifespan compared to standard screens, eliminating frequent downtime from rust degradation.
For arctic operations such as Russia railway project (-38°C), we reengineered every system for deep-freeze resilience. Cryogenically-tested Q355D/Q355E steel frames prevent brittle fracture, while nickel-infused welds maintain structural integrity. Critical components feature integrated heating: vibratory motors prevent oil solidification, hydraulic systems use Arctic-grade fluids, and electrical cabinets with dual-layer insulation house cold-rated Schneider/DELIXI components. The result? Uninterrupted 14-month operation.
Technological Innovation
Beyond environmental mastery, we embed reliability into every build. ROSTA anti-vibration mounts absorb 30% more stress than conventional springs, prolonging structural life. Smart PLC controls with IoT connectivity enable real-time performance optimization and predictive maintenance alerts. Our end-to-end service approach ensures seamless integration – from analyzing your raw material samples to designing site-specific circuits, whether deploying compact 3-in-1 mobile units or custom stationary plants.