rev jaw crusher on jackleg 1100mm 700mm

Industry Background: The Demand for Mobility in Primary Crushing

The aggregate, construction, and recycling industries face a persistent challenge: the need to process raw material at the source. Traditional fixed-plant primary crushing setups are capital-intensive and logistically cumbersome, requiring significant civil works for foundations and extensive on-site assembly. This lack of mobility is a major bottleneck for short-term projects, remote sites, or operations where the feed material is spread over a large area. The industry has increasingly turned to mobile tracked crushers as a solution. However, not all mobile solutions are created equal. The key engineering challenge lies in balancing formidable crushing power—necessary for reducing large, hard rock (e.g., 1100mm x 700mm feed size)—with rapid mobility, set-up speed, and operational flexibility on unprepared terrain.

Core Product/Technology: How does a REV Jaw Crusher on Jacklegs Combine Power with Agility?

The innovation of mounting a large jaw crusher (specifically a 1100mm x 700mm model) onto a chassis equipped with hydraulic jacklegs represents a significant leap in mobile crushing design. This configuration directly addresses the core industry challenges by decoupling the setup process from external infrastructure.

• Robust Crushing Core: At the heart of the system is the jaw crusher itself. A feed opening of 1100mm x 700mm is capable of accepting large blasted rock and demolition concrete, making it a true primary crusher. Key features of this crusher include:

  • Deep Crushing Chamber: Enhances throughput and reduces blockages.
  • Hydro-Pneumatic Toggle System: Provides automatic overload protection against uncrushable material (tramp metal), minimizing downtime and risk of damage.
  • Reversible & Replaceable Jaw Plates: Extends wear life and maintains optimal crushing geometry.

• Mobility & Stabilization Architecture: The true innovation lies in the integration with the mobile chassis.

  • Hydraulic Jacklegs (Outriggers): These are not simple stabilizers; they are heavy-duty hydraulic cylinders that lift the entire crusher off its tracks or axles. This achieves two critical objectives:
    1. It creates a stable, vibration-absorbing platform for high-impact crushing operations, protecting the chassis and ensuring consistent performance.
    2. It allows for precise leveling on uneven ground without the need for complex groundworks.
  • Track-Mounted Mobility: The crawler undercarriage provides low-ground-pressure movement around site and enables the unit to be repositioned under its own power in minutes.
  • Integrated Hopper & Pre-Screen: Many models include a vibrating grizzly feeder (VGF) that removes fines before they enter the crusher chamber, increasing efficiency and reducing wear.

Market & Applications: Where is this Mobile Crushing Solution Deployed?

This class of equipment serves markets that value operational flexibility and rapid deployment above all else.

• Contract Crushing: Companies that move from one client site to another find immense value in a machine that can be set up and crushing within an hour of arrival.
• Construction & Demolition (C&D) Recycling: Processing large concrete slabs and structural elements directly on the demolition site drastically reduces haulage costs.
• Quarrying: Ideal for satellite pits or for processing oversize material at different locations within a main quarry.
• Mining: Used in small-to-medium scale mining operations for primary crushing where fixed infrastructure is not feasible.

The tangible benefits across these applications include:

Benefit	Impact
Reduced Haulage Costs	Crushing at source eliminates transporting raw material to a fixed plant.
Rapid Setup/Tear Down	Jackleg system allows movement from one site to another in hours, not days.
Operational Flexibility	Ability to follow the face or move between multiple stockpiles maximizes utilization.
Lower Capital Outlay	Eliminates need for concrete foundations and extensive fixed plant infrastructure.

Future Outlook: The Road Ahead for Mobile Primary Crushing

The evolution of these machines is tightly coupled with broader industry trends towards automation, sustainability, and data-driven decision-making.

1. Electrification & Hybrid Drives: With increasing pressure to reduce carbon footprints and noise pollution, future models will likely incorporate hybrid diesel-electric drives or full electric-plug-in options for quarry applications, allowing for zero-emission operation when grid power is available.
2. Advanced Automation & Telematics: Integration with IoT platforms will enable real-time monitoring of wear parts, power consumption, and production metrics. Predictive maintenance alerts will become standard, further maximizing uptime.
3. Enhanced Intelligence: Automated setting adjustment systems that optimize crusher parameters based on feed material will improve product consistency and throughput without operator intervention.

FAQ Section

Q1: What is the typical production output range of a jaw crusher with a 1100x700mm opening?
A1: Output is highly dependent on feed material characteristics (hardness, abrasiveness) and the closed-side setting (CSS). However, such a machine can typically produce between 150 to 400 tonnes per hour in competent rock like granite or basalt.

Q2: How long does it take to set up the crusher using the jackleg system?
A2: A competent operator can typically deploy the jacklegs, level the unit, and be ready to start crushing in under 30 minutes from arriving at a new location.

Q3: Can it handle reinforced concrete (rebar)?
A3: Yes. The hydro-pneumatic toggle system provides excellent protection against tramp iron. The crusher can typically process reinforced concrete; however, regular cleaning of the crushing chamber may be required if rebar becomes tangled.

Q4: What kind of fuel consumption can be expected?
A4: Fuel consumption varies with load but generally ranges from 25 to 45 liters per hour under normal operating conditions for this size class of machine.

Case Study / Engineering Example

Project Profile: Urban Redevelopment Demolition Site

• Client: Major civil engineering contractor

• Location: City-center redevelopment project

• Challenge: Demolish a multi-story reinforced concrete structure and process over 80,000 tonnes of resulting rubble within tight time constraints. On-site space was limited, truck traffic was heavily restricted during daytime hours due to city ordinances,
  and exporting all material to a distant recycling center was cost-prohibitive.

• Solution Implementation: A track-mounted REV jaw crusher (model with 1100mm x 700mm feed opening) was selected as the primary on-site processing unit.

  1. The machine was positioned directly adjacent to the demolition area on prepared but unpaved ground.
  2. Using its hydraulic jacklegs,
     it was leveled and stabilized within minutes,
     independent of any external equipment.
  3. Large slabs of concrete with embedded rebar were fed directly into the crusher by excavators.
     4.The crushed product (-200mm) was then conveyed to secondary impactors stationed further away,
     creating certified recycled aggregates (20mm down).

• Measurable Outcomes:

  • Productivity: Achieved an average throughput of over 280 tonnes per hour,
    completing primary crushing ahead of schedule.
  • Cost Savings: Reduced haulage costs by an estimated €120,
    000 by avoiding over 4,
    000 truck journeys off-site (based on local haulage rates).
  • Environmental Compliance: Enabled round-the-clock processing while complying with daytime traffic restrictions; crushed material was reused on-site as sub-base,
    closing the recycling loop locally.
    Uptime: Recorded operational availability exceeded 95% throughout the project duration,
    attributed largely to effective pre-screening removing fines
    ,and robust tramp iron protection preventing major breakdowns