GRANITE AGGREGATES

FLEX-MAT Type D

Virginia, USA.

Situation

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Quarrying operations running a combination of static and rigid screening media; polyurethane panels on the top deck and woven screens on the bottom ones.

PROBLEM

Lacked capacity and throughput due to low open area, poor material stratification as well as severe blinding & pegging issues on the middle deck.

  • SETUP: 1″ woven over ½” woven over a 4mm polyurethane panel.
  • The bottom deck would blind over, carrying fines forward into the plant and adversely affecting the quality of the finer products in both cleanliness, and flats & elongated.

SOLUTION

Installed MAJOR’s FLEX-MAT Type D, eliminating pegging and blinding of the middle deck.

BENEFITS

  • FLEX-MAT helped the quarry achieve approximately 450 TPH of base production versus an initial base production rate of 150 TPH.
  • No quality issues on cleanliness for flats & elongated.  The operation ran base products with SMA products (extreme flats & elongated sensitive).
  • The operation plant was set up to run stone matrix asphalt (SMA) products which are extremely sensitive to flats & elongated particles.
  • FLEX-MAT tripled the productive operational life of the middle deck media versus woven.

A 200% INCREASE IN VOLUME REPRESENTS AN ANNUAL ADDITIONAL TONNAGE OF 720,000 TPY BASED ON A 2,400 HOURS OPERATION.