All About Aggregate Screening Equipment
What is an Aggregate Screen?
Aggregate screens are separation machines used to sort bulk aggregate materials by size after being crushed. Aggregate screening equipment uses a mesh screen to catch larger materials (such as stones) while allowing smaller particles (such as sand and gravel) to pass through holes.
These screens can have one, two, or even three or more sorting decks, depending on the scale of operations. Each deck has different-sized openings, starting from larger ones on the highest level for larger cuts of material and smaller ones on the second and third levels for finer cuts. Once sorted by size, these materials are used as components for different products, such as gravel or concrete.
Some aggregate screens use vibratory technology to move particles from one end of the screen to the other, creating a highly accurate separating process by transporting smaller particles to the screen while leaving larger ones on top.
What Are the Different Types of Aggregate Screens?
Aggregate vibrating screens come in two primary types: horizontal and inclined. They are used for different applications, but both use vibratory technology to sort equipment by size.
Inclined Screens
Inclined screens primarily screen bulk aggregate materials. Typically, these inclines range from 15-22 degrees. Incline screens excel at processing large volumes, using less energy and requiring a lower stroke due to the incline. On the other hand, they are less effective at screening accurately than horizontal screens.
Horizontal Screens
Horizontal screens separate aggregates more thoroughly than inclined screens. They are also good for screening wet materials. However, they are much slower at sorting materials than inclined screens, making them less useful for larger-scale screening jobs.
Portable Screens
Portable Screen Plants screen materials at the same rate as horizontal screens. The only difference is that they’re on wheels and can be moved around on-site or throughout different sites. These highly flexible screens are ideal for jobs that would normally require multiple screens in different locations. They’re also an excellent way to save money if you aren’t going to be using them in a single spot long-term.
Aggregate Screening Equipment Sizes
Aggregate vibrating screens come in various sizes. The GK aggregate screens range from 5’ x 12’ to 8’ x 24’ in double-deck and triple-deck sizes. The customizable sizes allow for easier installation and make it easy to choose the perfect size for your aggregate screening load sizes. Larger screens screen loads more efficiently but aren’t always necessary for smaller screening operations.
The size of your aggregate screen will depend on what it will sort. Some of the standard aggregate screen size modifications include:
- Incline
- Maximum capacity
- Number of decks
- Spray nozzle systems
- Size and material of screening media
Screening Media
The type of material being processed and the desired end product influences the size and material of the screening media. Screening media is the mesh that allows smaller aggregates through while moving bigger ones forward. The type and size of media depend on how fine the screened materials are. Here are some of the most common screening media materials:
Rubber
Rubber media is good at withstanding impacts and is ideal for high-wear wet and dry material applications.
Polyurethane
Similar to rubber, it lasts longer than other media types but has smaller openings. It is often used to screen wet and adhesive materials.
Wire
Flexible, able to screen various materials, and great if you switch media often.
Steel
Cheaper than rubber but needs to be replaced more frequently. Protects against corrosion and sticking.
Screening media needs to be replaced every so often due to regular wear and tear associated with screening. General Kinematics DURO-DECK™ Screening Media can replace old screening media and keep aggregate screens up and running.
How Do I Choose the Right Aggregate Screening Equipment?
No aggregate screen will be one-size-fits-all. Most aggregate vibrating screens are custom-made based on the processing needs of the recipient. Here are a few factors to consider when buying an aggregate screen:
- Amount of material processed: Screening more materials per hour means you’ll need a greater Screen capacity and size.
- Type of material: Larger materials will need larger mesh sizes, while smaller materials will require smaller mesh sizes. Finer materials may need higher stroke as well.
- The moisture content of material: Wet materials work better with rubber and polyurethane meshes.
- Size and amount of separation: The more size variation you want, the more decks you’ll need.
If you’re looking for an aggregate vibrating screen that’ll withstand wear and tear, General Kinematics’ Inclined Aggregate Screens and Horizontal Aggregate Screens are custom-made and built to last, so you can focus on processing more material, not repairing your screen. If you want to learn more about our custom aggregate solutions, contact one of our experts today, and we’ll take your aggregate screening process to the next level.
