Orange Crush

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, then you have to have a big crusher to keep up with demand. Even though Tinton Falls, NJ-based Stavola Contracting had a high-production impact crusher, the company's appetite for recycled material was much greater than its existing impactor could deliver in an eight-hour day.

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 to produce more than 250,000 tons of recycled asphalt and concrete annually, or would he make the investment in an ultra-high production impactor and circuit to keep pace with consumption? "We were running the Tinton Falls crushing circuit 10 to 12 hours per day, five to six days per week just to keep up with demand," says Stavola.

High RAP demands

Feeding a constant flow of recycled asphalt to Stavola Contracting's asphalt plant and paving operations throughout central and northern New Jersey was a primary culprit in pushing the company's previous crusher to its limits. Ten asphalt plants — including the largest batch plant in the state of New Jersey — produce in excess of two million tons of asphalt annually.

The past couple of years have seen a rollercoaster ride for liquid asphalt prices, and today's New Jersey price index stands 30 percent higher than it was just one year ago. Having enough properly-sized RAP is as critical as ever for Stavola Contracting to help control the production costs of asphalt. The company runs RAP in a majority of its mix designs, up to a maximum of 20 percent. "Last year, we used approximately 100,000 tons of recycled asphalt in our mixes," comments Stavola.

A variety of spec sizes are needed to satisfy the company's craving for recycled asphalt. A minus 1/2-inch RAP is mixed with the company's top course designs, while a one-inch minus recycled spec product is reserved for its base mixes. The company also sizes a 1 1/2-inch minus RAP product to be used as road subbase.

The vast demand for a variety of recycled product sizes led Stavola to the conclusion that the company needed a versatile crusher that would efficiently recycle both heavily reinforced concrete and asphalt. In addition, the crusher would have to feature high production tonnages with little recirculating load in order to eliminate the company's high overtime expenses.

Big impact

The company's previous crushing circuit at its Tinton Falls facility included a horizontal shaft impact crusher with a 56-inch x 35-inch feed opening. Although crushing up to 300 tons per hour (TPH), it could just not produce enough spec recycled material in an eight-hour day.

After some market research on mega production impactors, Stavola found a solution to his problem. It was in the form of a colossal horizontal shaft impact crusher from Eagle Crusher Company and its dealer, Capitol Equipment, that would easily crush enough material to feed Stavola Contracting's need for recycled materials and even leave room for expansion.

One of the primary reasons for selecting the Eagle Crushing impactor was the company's long-standing relationship with the manufacturer. "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," explains Stavola. "Eagle Crusher Company and their dealer (Capitol Equipment) have supported our other crushers very well and have earned our trust."

After considering Stavola Contracting's needs, Capitol Equipment recommended the UltraMax UM69 impactor for the Tinton Falls facility. The horizontal shaft impact crusher has an enormous 69-inch wide by 42-inch high feed opening. Although a majority of the asphalt loaded into the crusher comes from the company's three milling machines, Stavola often feeds much larger slabs into the impactor. "We'll load whatever size asphalt that fits into the feed opening," claims 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 to 600 TPH, in which Stavola Contracting currently averages 500 TPH. With the industry's heaviest rotor, the impactor provides optimum penetration and energy to deliver efficient initial reduction, up to a 24:1 ratio, without sacrificing the impact forces necessary for secondary reduction.

Even when crushing RAP to the smallest, 1/2-inch minus spec size, Stavola estimates achieving at least 75 percent passing the 9/16-inch bottom deck screen on the first pass. This is critical when processing RAP, since every pass through the crusher increases the chance of the asphalt binder being broken away from the aggregate.

Two Cat 980 loaders with 7.5-cubic-yard buckets strain to keep the impactor's 19-cubic-yard feed hopper filled with material. "The UM69 keeps our loader operators moving to keep up with it," says Stavola. The all-electric circuit is powered by a 300 hp motor. Once crushed, the recycled material outlets onto a 48-inch by 40-foot discharge conveyor.

Crushed material is sorted by an Eagle Crusher 6- by 20-foot, triple-deck screening plant. Stavola Contracting uses a variety of screen sizes on each deck, depending on the final size of the material being processed. The entire circuit, including the BTI breaker mounted to the hopper to prevent material bridging, is operated by a single person in the control tower.

Efficient operation

Through a collaborative effort between Stavola Contracting and Capitol Equipment, the circuit's design was laid out for efficiency and to lower costs. According to Bob Mrozinski, territory manager for Capitol Equipment, "We raised all of the circuit's major components two feet by using Sona-Tube bases to better keep the crushing area clean."

Since installing the new UM69 impact crusher and circuit, which began operation in June 2004, Stavola's plan has been realized. Significant overtime hours are now history 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."

Stavola Contracting opted for no grizzly on the feeder to improve the circuit's production. Stavola explains, "In order for a grizzly to be efficient, you need about a three- to four-inch separation between the bars. With our final product, we would have too much recirculating load, which defeats the purpose of a grizzly." He adds that the recirculated material would dump into one side of the crusher, resulting in uneven bar wear and increased wear costs.

The impactor's durability and ability to handle massive slabs of RAP and heavily reinforced concrete has also impressed Stavola Contracting. According to Mrozinski, "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." With the combination of recycled asphalt and concrete material crushed by Stavola Contracting, the UM69's proprietary N1 alloy steel blow bars from Eagle Crusher are delivering approximately 32,000 tons of finished product per set.

Switching from crushing concrete to a 1 1/2-inch recycled asphalt final product could not be any easier. 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 final product.

When crushing to smaller RAP sizes, the crew switches out the middle and bottom deck screen cloths to size openings that will deliver the desired gradations. More recently, Stavola has added a second, 5-foot by 12-foot screen to the circuit in an effort to reduce the number screen cloth changes and improve screening efficiency.

Extremely quiet

The UM69 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 to be less than 65 decibels (dBA) at adjoining properties.

Sound measurements taken next to the impactor indicate that it runs quieter than the average lawnmower. 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.

More important than quiet operation, the new impactor circuit has surpassed established goals for Stavola Contracting. It continues to eliminate extremely high overtime costs and improves the operation's productivity to keep pace with demand.

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."

Vermeer T1055/T1255 Terrain Levelers

The T1055/T1255 Terrain Levelers can work in applications such as surface mining, over-burden removal, road construction/reconstruction and soil remediation.

  • T1255 has a 600-hp CAT engine and is capable of cutting 12 feet wide and 27 inches deep in one pass
  • T1055 has a 425-hp Cat engine and can cut 11 feet wide and 24 inches deep in a single pass
  • Tilting cutter drum with two-direction leveling

Roadtec RX-900 Cold Planer

The RX-900 cold planer is available with an 860-hp Caterpillar or optional 950-hp Cummins diesel engine.

  • Three- or four-track assemblies
  • Cuts 14 inches deep and from 7 feet 2 inches to 12 feet 6 inches wide
  • 42-inch front load-out conveyor
  • Hydrostatic drive for propulsion and conveyor system
  • Working speeds up to 128 fpm
  • Proportional joystick controlled steering with coordinated, crab, front-only and rear-only modes

Grasan KR1010 Compact Rubble Plant

Grasan's KR1010 compact rubble plant sets up in 15 minutes and operates in tight quarters.

  • Hazemag primary impact crusher with 25-inch high by 40-inch wide feed opening
  • Crushes up to 150 tph
  • 240-hp John Deere diesel engine
  • Variable-speed heavy-duty grizzly feeder
  • Transports over the road fully assembled

Dillman Incline Recycle System

The recycle system from Dillman Equipment can be added to batch or drum plants.

  • Rugged, all-welded construction with single or multiple bin arrangements
  • Large capacity bins feature sidewalls with 32" x 24" gate openings and large capacity 36-inch feeder
  • Portable, stationary or skid mount arrangements equipped with various screens, grizzlies, optional lump breaker, bin extenders belt scales, AC, DC, and eddy current drive package systems

Reliable Asphalt In-Line Recycle Systems

Reliable Asphalt Products offers a line of in-line recycle systems.

  • Portable or stationary arrangements complete with all the necessary components to provide recycle capability at any type of plant
  • Includes a large capacity recycle bin with grizzly and troughing feeder conveyor
  • Lump breaker features 250-tph capabilities, counter-rotating floating rotors and replaceable hardened steel teeth with chrome-carbide tips

Marini MP 2100 Cold Mill

The MP 2100 cold milling machine has a 6-foot 6-inch cutting drum width and a milling depth to 12 in.

  • Cutting drum mechanically driven
  • Interchangeable tool holders
  • PLC with CAN-BUS technology provides real-time control of major machine functions
  • 598-hp diesel engine

Terex/CMI PR950 Roto-Mill

The PR950 Roto-Mill Pavement Profiler makes cuts up to 15 inches deep with a standard full-lane cutting width of 86 inches at working speeds reaching 170 fpm.

  • 950-hp Cummins six-cylinder diesel engine
  • Power-band, V-belt direct-drive system
  • Quick-mount cutter design with optional 150-inch cutting drum
  • Four steering modes
  • 42-inch high-capacity conveyor swings 60 degrees to the left or right of center
  • Three- or four-track designs

Bomag MPH362 Asphalt Recycler/Soil Stabilizer

Bomag's MPH362 rear-wheel drive asphalt recycler/soil stabilizer is powered by a 360-hp Cummins N14 water-cooled diesel engine.

  • 187-fpm maximum working speeds
  • Automatic Power Adjustment System (APA) automatically adjusts forward travel speeds to match application and material being processed
  • Three rotor configurations
  • 12-inch maximum cutting depth with recycler rotor; 14 inches with stabilizer rotor; 21 inches with deep stabilizer model

Marini MP 1300 Cold Milling Machine

Marini's MP 1300 cold milling machine has a cutting width of 51 inches and a cutting depth of 12 inches.

  • For removing old or damaged roads
  • Front-loading foldable conveyor
  • Cutting drum is mechanically driven through V-belts
  • Interchangeable tool holders
  • Center-position drum allows the operator to steer the rear tracks in order to reduce curve radius and mill near curbs

Caterpillar PM-201

Caterpillar's PM-201 features a 650-hp Cat C18 engine with ACERT technology.

  • 83-inch rotor width
  • 12-inch rotor depth
  • 41,310-pound operating weight
  • Load Sensing Propel System
  • Choice of three rotor designs
  • High capacity, versatile conveyor

Terex RS800 Reclaimer/Stabilizer

The RS800's heavy, unitized mainframe with center-mounted 800-hp Caterpillar engine and cutter distribute the machine's 67,500-pound weight and horsepower for high production.

  • V-belt driven
  • Four-speed rotor transmission
  • Full depth cutter for up to 20-inch cutting depth and 10-foot width

Wirtgen W 35 DC Cold Mill

The Wirtgen W 35 DC small milling machine is used for cold planing small areas for the partial rehabilitation of pavement, milling around manhole covers, and placing and removing road markings.

  • Can be equipped with optional short conveyor
  • Standard all-wheel drive
  • Ergonomic design with operator's station located over the cutter drum
  • 14-inch cutting width
  • 4.3-inch cutting depth
  • 82-fpm operating speed
  • 10,031-pound operating weight
  • 57-hp engine

Caterpillar PM-200

Caterpillar's PM-200 features a 575-hp Cat C18 engine with ACERT technology.

  • 79-inch rotor width
  • 12.5-inch rotor depth
  • 68,122-pound operating weight
  • Load Sensing Propel System
  • Computerized monitoring system in operator's station

Wirtgen W 2000 Combo Cutter

The new W 2000 Combo Cutter milling machine can change drum widths easily from 24 to 36 to 48 inches in width.

  • 565-hp engine
  • For shoulder widening
  • Cuts zero to 12 inches deep
  • Wirtgen Type III Quick Change tooth holder system
  • Segmented rear moldboard with independent control and side-shifted material discharge conveyor to maximize material flow

Eagle Crusher UltraMax 1600-69

Eagle Crusher's latest addition to its UltraMax Series, the 1600-69, features a sculptured three-bar rotor made of solid steel.

  • Portable high-volume, primary/secondary impact crushing and recycling plant
  • 800-tph capacity
  • Three-stage crushing action
  • Several power options: 500-hp electric, 800-hp electric or 521-hp diesel engine
  • UM 69 impactor with a 68" x 20' feeder

Dynapac PL 350 S Planer

The PL 350 S cold planer has a 4-inch cutting depth and a 14-inch working width.

  • 60-hp Cummins B3.3 diesel engine
  • 6,174-pound operating weight or 9,481-pound maximum weight with ballast
  • Up to 82-fpm working speed and 3.6-mph transport speed
  • 127-gallon water and 32-gallon fuel tank

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