Application: Recycle Concrete as Asphalt
When your company runs the largest impact crushing recycle yard on the East Coast, has 10 asphalt plants that consume large volumes of RAP, and operates a highway and heavy contracting business that requires thousands of tons of recycled concrete for its municipal and private customers, you have to have a big crusher to keep up with the demand.
So Rick Stavola, president of the 50-year-old, family-operated contracting business faced a dilemma. Would he continue to pay large sums of overtime expenses to his employees to produce more than 250,000 tons of recycled concrete and asphalt annually, or would he make the investment in an ultra-high production impactor and circuit to keep pace with consumption?
After some market research on mega production impactors, Stavola found a solutions to his problem. It was in the form of a colossal horizontal-shaft impact crusher from Eagle Crusher Company and its dealer, Capitol, that would easily crush enough material to feed Stavola Contracting’s huge appetite for recycled materials and even leave room for expansion.
“We already have UltraMax 1400-45 impactor circuits at our two other recycling facilities, and we use a portable 1200-25 closed-circuit crusher for our contract crushing. Eagle Crusher Company and their dealer (Capitol) have supported our other crushers very well and have earner our trust,” comments Stavola.
The 56-inch by 68-inch solid-steel rotor lies at the heart of the three-stage crushing action, and the impactor is capable of producing between 400-600 TPH, in which Stavola Contracting currently operates its UM69 at 500 TPH. With the industry’s heaviest rotor, the impactor forces necessary for secondary reduction. Even with the large feed material encountered at the Tinton Falls facility, Stavola estimates the impactor crushes more than 85 percent of the feed to a 1.5-inch minus spec product on the first pass.
Through a collaborative effort between Stavola Contracting and Capitol, the circuit’s design was laid out for efficiency and to lower costs.
Since Installing the new UM69 impact crusher and circuit, which began operation in June, Stavola’s plan has been realized. Significant overtime hours are now a thing of the past with the new crusher’s increased production. According to Stavola, “We now run the crusher approximately 4.5 days a week and only 8 hours per day, eliminating the need for overtime.”
The impactor’s durability and ability to handle massive slabs of heavily reinforced concrete have also impresses Stavola Contracting. We loaded a complete 6-foot-long, 2,500-pound Jersey barrier into the crusher, and the UM69 ate it up in a matter of seconds.
Switching from crushing concrete to an asphalt final recycled product could not be any easer. It takes just a matter of minutes to clear the circuit and move the 100-foot radial stacker a couple hundred feet to begin stockpiling the different product.
The mammoth UM69 also runs surprisingly quiet when devouring feed material, leading the way to a very quiet overall crushing circuit – one that is well within the state guidelines for noise regulations. The NJ State regulations require that continuous airborne sound levels be less than 65 decibels (dBA) at adjoining properties.
Sound measurements taken next to the impactor show that it runs quieter than the average lawn mower. At a 50-foot distance, sound levels generated by the impactor are comparable to that of the dreaded morning alarm clock, and at 100 feet are approximately the same as conversational noise levels. “This is one of the quietest impactors and crushing operations that I have been around. Even in the control room, which is right beside the hopper and impactor, the noise levels register only 74 dBA,” says Mrozinski.
Now that the crushing circuit is in full swing, if demand requires, Stavola has plenty of room to boost production. “We are extremely pleased with our new Eagle Crusher impactor and crushing circuit. The UM69 has helped us to save approximately $0.40 per ton in overtime costs alone, and its performance has exceeded our expectations.”
When Steve Bevilacqua decided to get back into the asphalt business, he knew he wanted to do a number of things differently this time around. He had plans to steal a page from the ready-mix playbook and add an asphalt-on-demand component to the new operation. He wanted to keep operating costs down by protecting his aggregate from the elements. He wanted to be a smaller yet more responsive company than his previous undertaking.
In spite of all this desire for change, however, there were some things that had proven so positive in the past, so tried-and-true that, to change them would simply be counter-productive. His choice of asphalt plant (a 300 tons/hour ADM MileMaker) and crushing plant (an Eagle 1200-25CC) were two of those items that are back for an encore. Knowing what to change and what to keep intact, coupled with a great relationship with his equipment dealer, has resulted in Bevilacqua Asphalt, one of the most successful, innovative, asphalt plants in southeastern Mass.
Located on 27 acres in the town of Uxbridge, Mass., Bevilacqua Asphalt is the product of the ever-active imagination of its owner and president, Steve Bevilacqua. Fresh off a retirement shorter than most Hollywood marriages, Bevilacqua decided he had far too much unfinished business and set to work building a new operation.
“I guess I’m just not one to sit around for very long—it’s not in my DNA,” he says. “So after three years of fishing and relaxing, I started putting together plans for a new asphalt operation, and one of the first people I mentioned it to was Seamus Crotty, from Capitol EQ2 (Mechanicville, NY), the Eagle Crusher salesman who called on me at my previous business. Not long afterward, he contacted me to say he had a great deal on a used Eagle crushing plant and it was the same model I had been using for years. I immediately told him I’d take it.”
It’s important to note that, at this point, Bevilacqua had yet to apply for the permit for his new operation. But his preference for that crushing plant—based on its performance at his previous operation—and the trust he placed in Crotty’s judgment was so strong, there was no hesitation.
“We had it sent back to Eagle for a full refurbishing, had it painted my colors, and at that point, without turning a shovelful of dirt, I guess was officially back in the business.”
The Eagle 1200-25CC plant was of particular interest to Bevilacqua, not just because it had already proven itself, but because he knew his new business would have a sizeable focus on RAP. Many of the 1200’s strengths, he says, are geared for that application.
“The 1200 is a closed-loop impact crusher and it’s definitely the best tool for the job I had in mind,” he says. “Because it has a double-deck screen and offers such a long screen deck—16 feet long by five feet wide—it screens out the highest volumes of material possible before sending it back for recirculation. I’ve seen other similarly-sized crushers and demoed some, but none of them compare in terms of efficiency or performance.”
Minimizing the amount of recirculated material, he says, has also paid dividends in lowering associated maintenance costs—particularly wear parts.
“Blow bars are one of the major wear part components on this machine and I’ve been getting some outstanding life out of mine—roughly 30,000 tons of material per set. That comes out to just pennies per ton in costs. I’m certain that is a direct result of the fact that so much material is getting screened out before entering the recirculation loop.”
Capitol’s Crotty sheds some additional light on why that particular crusher was the ideal fit for Bevilacqua’s needs. “Though he doesn’t do a lot of it, Steve does crush asphalt and concrete to sell as a base material,” he says. “With the 1200, he has the ability to so with only minor modifications to the plant. It is an extremely versatile piece of equipment, capable of doing rock, gravel, recycled materials, and so on. But right now for Steve, producing feedstock for RAP is its biggest strength and I know he’s getting a consistent 150 tons per hour of 3/8-minus material.”
South Plainfield, NJ
Application: Recycle Concrete
Built in the 1960s, the Ecolab facility encompassed 24 acres of land in the heart of Woodbridge’s industrial are. Located at the port and right off the NJ Turnpike with nearby rail service, the site is a prime location for warehousing and distribution. Over the years, Ecolab built onto the original building and added multiple levels to where today’s facility encompassed more than 235,000 square feet of factory and office space.
Three-Inch Centered Rebar
By far the lion’s share of the recyclable material on-site came from the concrete building and asphalt parking lot. An estimated 45,000 tons of material – 35,000 tons of concrete, masonry block and brick and another 10,000 tons of asphalt – was crushed via the company’s Eagle Crusher UltraMax 1000-15CV horizontal shaft impact crushing plant.
Crushing both the concrete and asphalt materials were prime examples of the twists commonly found on this project. The larger and more heavily reinforced footings and foundations posed a challenge for the demolition crew. “On a scale of one to 10 (10 being the toughest to recycle), I would rank this a 9.5 to 10,” says Carl Franzetti, site supervisor for Dallas Contracting. “This building was built like a bunker.”
The foundation’s construction included rebar positioned on 3-inch centers. At the height of the demolition, Dallas Contracting and the crusher were churning out three to four 30-yard containers of rebar a day. “The builders went crazy with the rebar and concrete.”
The impactor’s 44-inch by 41-inch solid steel rotor withstands the abuse delivered by the reinforced concrete. In tough recycle applications such as this, Dallas Contracting opts for medium chrome blow bars to offer the right balance of wear life without bar breakage. “Even when recycling this type of heavily reinforced concrete, we will get 20,000 tons out of a set of blow bars,” says Kozul. The plant’s in-line magnet separates the rebar from the concrete.
Switching from crushing concrete to asphalt did not pose a problem. “We just moved the conveyor, so the asphalt discharged into a separate pile,” said Franzetti. Although the impactor may be able to get better wear with an Eagle Crusher high chrome blow bar when crushing asphalt, on a job this small it was more efficient to crush with the medium bars.
According to Dallas’ Kozul, owning a portable crushing plant like the UltraMax 1000-15CV made economic sense. Developer Adler agreed, adding: “It saves us money at both ends, first hauling the old material off-site and second bringing in new for construction. It’s good for everyone involved.”
“Buy crushing on-site, we typically save our customers $13 per ton in trucking and dumping fees associated with hauling the materials to a recycling yard,” claims Kozul. On a job the size of Ecolab, this adds up to more than $500,000 savings for the customer, just on the recycling costs alone.
Another key to the savings, according to Kozul, was selecting a crushing plant that was truly portable. Dallas Contracting can move its machine on-site within an hour. “We have to remind our customers that the same day we move in the plant we want to be crushing,” says Kozul. With such a portable plant, Dallas Contracting can process small custom-crushing jobs as well as the large demolition projects, and it gives the company some scheduling flexibility. “When we crushed the first material stockpile at the Ecolab project, we were able to quickly move the plant and crush another job while we were waiting for the excavators to size more concrete in Woodbridge.”