OUR STORY

Eagle UM-69
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.

Efficient Operation
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.

Extremely Quiet
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.”