Getting it done: concrete crushing firms use a variety of equipment to run profitable operations - Concretel/Asphalt Focus

C&D Recycler, March-April, 2003

The practice of crushing and recycling concrete and asphalt has flourished because it can save and make money for contractors.

Often, the savings come in the form of holding down or largely eliminating hauling costs when crushing is on site. Money can be made when materials are re-sold after being processed.

But even though the economics of aggregates recycling have proven worthy of contractor attention, that doesn't mean that profit margins are wide enough for any and all applications.

For recycling to make sense, contractors have to know their end markets, do some calculations relating to any given project and use the right equipment to get the job done. Following are snapshots of a couple of different crushing firms and some of the decisions they have made to make concrete and asphalt crushing effective and profitable.

HAVE CRUSHER, WILL TRAVEL

"We'll go just about anywhere to crush a minimum of 25,000 tons of concrete or asphalt rubble, demolition debris, limestone; even slag in steel mills," says Scott Weber, vice president of WeberSand & Gravel Inc., Lake Orion, Mich.

"On the average, we move our entire operation about once a week: crusher, screen, conveyors and stackers," notes Weber. "Most of our business is in Michigan, northwestern Ohio and northern Indiana, but we are bidding jobs right now in Florida, Alabama and Arizona," he adds.

Portability is thus a key factor for Weber's operation. "To move that often, go that far and still be competitive, you need equipment you can move quickly and economically, and your production has to be extremely efficient and dependable," he remarks.

Weber Sand & Gravel Inc. was established in 1946 by Scott's father and mother, Jack and Gerry Weber. The company has been family owned and operated ever since. Scott credits the company's success to family effort and having quality equipment that is right for job. Scott's brother, Greg, also a vice president, operates the sand and gravel business. Gerry Weber is president and still very much involved in the company.

"Dad and I used to work together a lot in the contract crushing operation," Scott Weber notes. "There were times when he'd object to my bidding a certain type of job or bidding at a certain price and say it wasn't worth it; we just couldn't make a profit on it. I'd insist that we could. Finally he'd usually give in; we'd get the job and do just fine."

That doesn't mean pre-job calculations go out the window, Scott is quick to note. "Don't misunderstand--we're not always the lowest bidder. But when we are underbid and somebody else gets the job, I don't fret over it because so often the customer ends up being disappointed and we get his next job. Once we get a customer, we keep him," he adds.

"If you make customers happy, the word gets around," Scott continues. "We're known as being very professional. That's the result of three key factors. First, our family name and reputation is on the line with every job; so we always do what we say we will. We guarantee price, tonnage, specifications and schedule. Secondly, we don't just stand around and supervise. We do the work, and nobody works as hard or efficiently as the owner does. Thirdly, we use top-quality equipment designed for our needs. That's absolutely essential."

The Webers have worked with Grasan Inc., Mansfield, Ohio, on their system design. "For our contract crushing operation, we have a complete system engineered and manufactured by Grasan: KRH1515 primary impactor plant, 7-feet by 20-feet screen plant, return conveyor, radial stackers and generator and controls housed in a 30-foot trailer," says Scott. "Everything is road portable. The impactor itself is a Hazemag APPH type with the automatic hydraulic cylinder system for greater crushing capacity, smoother operation and more uniform products. We can stack crushed materials in standard conical piles, or we can stack in windrows with a telescopic radial stacker for a more uniform material mixture," he remarks.

"We can crush as much as 900 tons per hour of limestone or concrete rubble down to one inch by three inches, or 500 tons per hour of asphalt rubble down to 5/8-inch minus while using only two blow bars instead of the possible four," he continues. "We can tear the plant down, blow it clean with compressed air, move it to a new location within a reasonable distance, set up and be crushing again in 12 hours or less, as a rule. That comes from two things: one is practice; the other is the custom design."

Certain hardware choices have helped the Weber plant maintain its portability. "We had Grasan engineer both the crushing plant and screening plant with quick-disconnect pins instead of bolts for almost anything we have to dismantle or take off for over-the-road travel," says Scott. "That saves a lot of time and hassle."

Scott says the pins offer several advantages. "It takes longer to work with bolts, the threads get worn after awhile, and it's easy to lose a nut or washer. The pins are quick, simple and chained to the equipment so you won't lose them. Grasan also designed a dust cover for the screen plant to make the whole operation cleaner and keep people in neighboring areas happier."