Project Background
With natural river sand becoming restricted in Australia, a major concrete producer needed 400 TPH of manufactured sand conforming to AS 1141 and AS 2758.1 for ready-mix concrete and pre-cast products.
Process Design
WSHT engineered a wet-process manufactured sand system with high-efficiency classification:
- Feed from a 10-20mm crushed rock stockpile via apron feeder
- Two B9100 VSI sand makers in parallel, each 200 TPH
- Two-stage wet screening (2-deck + 3-deck) with spray bars for fines removal
- Hydrosizer for fines (-75μm) classification and dewatering
- Thickener and water recycling system (90% water recovery)
Equipment Supplied
2× VSI sand makers, 5× multi-deck vibrating screens, 2× hydrosizers, 2× dewatering screens, slurry pumps, and a complete water treatment circuit. Centralized control with HMI touch-screen operation.
Installation & Compliance
Project delivered on a 7-month schedule, complying with all Australian mine safety, environmental and noise regulations. Plant noise level measured at 78 dB(A) at property boundary, 2 dB below local limit.
Performance & Results
Final manufactured sand meets AS 2758.1 specification with FM = 2.65, water demand 8.5% (target 9% max), 14-day concrete strength +12% over the control mix. Plant has been operating at 105% of nameplate capacity for the first 8 months.