On the move

Rock crushing machinery traditionally has had a hefty price tag of half a million dollars and up, but the emergence of small portable crushing plants at a fraction of the cost has made crushing more affordable.

In almost all instances, purchasing a rock crusher can and will pay off in the long run—and likely in the short run with some imagination and drive. Purchasing a rock crusher can be a step in the right direction to expanding a business and opening doors to new revenue streams.

Rock crushing involves using heavy machinery to break down large rocks into smaller pieces, also known as aggregate. While this process is fairly straightforward, the businesses that rely on it are varied.

The construction industry uses rock crushing, of course, as well as sectors ranging from industrial recycling and glass recycling to agriculture and infrastructure. Various industrial recycling businesses use rock crushers to recycle cement, gravel and other materials, which can help minimize waste.

In construction, aggregate bases are a requirement before pouring the foundation for most structures. In cases where a demolition precedes a new build, eliminating demolition disposal and aggregate purchase costs—as well as the transportation costs for both—can yield significant savings for the small to midsized contractor.

Benefits of a rock crusher

The ability to crush rocks brings various benefits, from reduced costs and increased productivity to enhanced sustainability and improved quality.

Owning a mobile crusher eliminates the costs associated with buying aggregate or lugging material off-site for processing or recycling. Instead, crushing, processing and recycling rock on-site can save labor, fuel and other costs.

Processing materials on-site using rock crushers enables the production of more aggregate in less time, with improved efficiency overall.

Eliminating the need to transport materials to crushing facilities can help reduce environmental footprint and carbon emissions. Plus, recycling prevents material from ending up in a landfill.

From construction site entrances to graveling roads to smaller fill that packs better, different sizes of aggregate can be required depending on the application.

By crushing rocks into specific sizes, crushers can help ensure that the aggregate fulfills the exact desired specifications and purpose.

Small, portable rock crushers such as Micro Crushers from Raleigh, North Carolina-based Senya can produce material down to 3/8-inch, and using the Micro Screen Plant can yield clean material graded to specific sizes for various applications.

All of this adds up to increased revenue for companies that use mobile crushers. A crush-on-site business model with a smaller and more portable crusher for those jobs under 10,000 tons can be hugely profitable. Besides controlling aggregate supply and disposal costs, the ability to offer crushing services or crushed rock materials to other businesses is an additional revenue stream.

Having the ability to crush on-site opens up increased opportunities to win more bids and land jobs that might not have made sense previously. Using “green” recycled materials provides an advantage in the bid process, too, as many jobs now require demolition debris to be recycled.

Choosing the right crusher

A few different factors can help guide the decision on which model best suits specific rock-crushing needs.

Traditionally, various machines are equipped with different crushing mechanisms intended for the three processing stages. These include the primary phase, in which larger material gets crushed to a small enough size input for the secondary crusher; the secondary phase, which further processes the aggregate down to meet the requirements of the tertiary, or final, crusher; and the tertiary phase, or final reduction stage, which refines the crushed stone and transforms it into the end product.

Crushers of various types are available for purchase.

Jaw crushers commonly are used in the primary stage to break up rocks between two opposing jaw plates. Although jaw crushers are ideal for handling rebar and wire in concrete, they also can work with many materials. They are by far the most popular style of crusher given their ability to handle most materials.

Jaw crushers produce material with more angular edges often preferred by engineers for their “gripping and setting” ability.

Impact crushers can be used in all phases and use impact forces by throwing the material against the outer wall of a drum to break the material down.

They help shape the aggregate into a more rounded material and can create finer materials. They are best for abrasive rocks and asphalt in warmer weather when the material can be soft and gummy.

An impact crusher’s blow bar and wear plate replacement can contribute to significant operation and maintenance costs. They are best for when their specific advantages are required.

Cone crushers have a large drum with a cone in the middle. The cone moves inside the drum to grind the stone into small pieces. They can handle medium-hard and hard materials, as well as some abrasive rocks. As they produce a finer final product, they’re often used in secondary and tertiary phases.

Rock crusher plants are a portable crusher plant that has various types of crushers—it is an all-in-one machine. They can incorporate dual-stage crushing units and screening integrated into one unit all mounted on a portable chassis. These models are the most versatile as they can be used to crush, screen and finish the entire crushing process.

Crushers also are available in portable, mobile and stationary options:

Portable crusher models can be moved around on a wheeled chassis. Although portable crushers are compact, they are affordable and could offer small and midsize projects all the benefits of larger crushers but with the advantage of being able to crush on-site.

Mobile crushers, though valued for their mobility once on the jobsite, are on a track, so they don’t have as much portability as other portable models. They also usually incur more operation and maintenance costs than stationary units.

Stationary crushers stay in one location—they can’t be moved once installed. These are traditional plants used by quarries and aggregate-producing operations.

Deciding factors

When deciding which type of rock crusher to purchase, operators should consider what material they work with the most. Choose accordingly, as some models are more suited to material of specific sizes and hardness.

Concrete, asphalt, brick and block are relatively soft and easily handled by most crushers. Natural stones such as granite and river rock, however, can be at least twice as hard.

Choosing a crusher designed to handle those harder materials can help ensure long-term durability, reliability and lower operating costs. Even on softer material, greater crushing power can offer advantages in productivity.

For operators with frequently changing jobsites and the need to move a crusher often, portable models offer the required mobility and flexibility. Processing on-site can yield tremendous savings by eliminating transportation costs, not to mention demolition disposal and aggregate purchasing costs.

Increased profitability

The U.S. produced about 1.5 billion metric tons of aggregate in 2023. The rock-crushing industry is highly profitable with many different types of businesses depending on the crushed stone, with concrete being the most recycled material in the world.

While rock crushing can be a great way to generate more income and cut costs, maximizing return on investment (ROI) requires knowledge of material end markets.

To increase crushing ROI, operators must conduct market research before purchasing a crusher. It’s crucial to understand factors such as the role of aggregate in your industry and the local demand for this material.

Additionally, market pricing research necessitates exploring aggregate purchasing costs and local demolition disposal costs.

Success can hinge on purchasing the correct equipment. While buying a cheaper or preowned model could seem like a budget-friendly idea, operating expenses could add up over time. Choosing a crusher with the latest cutting-edge technologies that is energy-efficient and requires little maintenance can lead to a better ROI by reducing your operating costs.

Finally, operators will need the correct permits. Depending on the industry and location, businesses could need a specific permit to avoid fines. Before getting started crushing, confirm with local and state authorities to ensure necessary clearances.

Rob May is general manager and sales director at Senya Crushers, a Raleigh, North Carolina-based manufacturer of concrete and rock crushers. Visit www.senyacrushers.com for more information.