What is Track-Mounted Impact Crushers?

A track-mounted impact crusher uses high-speed blow bars to strike material, causing it to shatter along natural fissures. Mounted on tracks, it moves easily around sites, ideal for secondary crushing, aggregate shaping, and recycling applications like concrete and asphalt.

This machine combines the crushing principle of an impactor with the go-anywhere capability of a tracked chassis. It’s a vital tool for many aggregate producers and recycling operations. ZONEDING MACHINE builds robust track impactors designed for performance and reliability in demanding conditions.

How Does Tracked Impact Crushers Differ from Jaw or Cone Crushers?

A track-mounted impact crusher uses a rotor with blow bars spinning at high speed to strike feed material. This differs from jaw crushers (compression between plates) and cone crushers (compression within a cavity), resulting in different product shapes and suitability for various materials.

How Impact Crushers Work

Inside an impact crusher (also known as HSI – Horizontal Shaft Impactor), material enters the chamber and meets a fast-spinning rotor fitted with blow bars (hammers).

• Impact: The blow bars strike the material with high force, shattering it.
• Rebound: Material pieces are thrown against stationary breaker plates (or curtains/aprons) lining the chamber, causing further breakage.
• Attrition: Particles collide with each other within the chamber, promoting cubical shapes.

Key Differences from Jaw and Cone Crushers

Impact crushers when product shape (cubicity) is critical, or for recycling applications.

Jaws are for primary breaking of large, hard rock.

Cones are excellent for secondary/tertiary crushing of hard, abrasive materials.

What are the Core Advantages of Choosing a Track-Mounted Impact Crusher? (Mobility & Crushing Principle)

The core advantages are its self-propulsion (tracked mobility) for easy on-site relocation and its impact crushing principle, which excels at producing highly cubical aggregates and efficiently processing recycled materials like concrete with rebar.

Unmatched Mobility

Like its tracked jaw and cone counterparts, the track-mounted impact crusher eliminates the need for:

• Building fixed foundations.
• Extensive site preparation for setup.
• Using external vehicles (like trucks) to move the crusher around the quarry, demolition site, or recycling yard.

This drastically reduces setup time and internal haulage costs, allowing the crusher to follow the material source or move easily between stockpiles. ZONEDING track units for reliable and efficient movement.

Superior Crushing Principle for Specific Applications

The impact method offers distinct benefits:

• Excellent Product Shape (Cubicity): The high-impact shattering and particle-on-particle collision naturally produce aggregates with a more cubical shape compared to compression crushers. This is highly desirable for concrete and asphalt production, meeting stringent specifications.
• High Reduction Ratio (Material Dependent): In suitable materials (like limestone or recycled concrete), impactors can achieve significant size reduction in a single pass. Pushing for a very high ratio (small output setting, high speed) on harder or abrasive rock (like some granite or river gravel components) will cause wear parts (blow bars, impact plates) to wear out extremely quickly. This drives up operating costs significantly. Aim for a reasonable reduction ratio based on material hardness (check Mohs hardness, Los Angeles Abrasion value) and abrasiveness (Silica content – SiO2%).
• Effective Recycling: Impactors handle heterogeneous materials like C&D waste well. The impact action can help liberate rebar from concrete, making downstream magnetic separation more effective.

These advantages make track-mounted impact crushers a preferred choice for final stage crushing in aggregate production and a primary tool in recycling yards.

Which Materials and Application Scenarios Best Leverage the Strengths of a Track-Mounted Impact Crusher?

Track-mounted impact crushers excel with medium-hard to soft, non-abrasive rock (like limestone, dolomite, gypsum) and are highly effective in recycling concrete (including reinforced) and asphalt pavement due to their ability to produce good shape and handle contaminants.

Ideal Materials

• Limestone & Dolomite: Widely used for producing cubical aggregates for concrete and road base. Impactors achieve good shape and high throughput.
• Sandstone (less abrasive types): Can be processed effectively.
• Gypsum, Shale, Coal: Softer materials easily crushed by impact.
• Recycled Concrete: Excellent at breaking down concrete while helping to separate rebar.
• Reclaimed Asphalt Pavement (RAP): Effectively liberates the aggregate from the bitumen binder.
• Bricks and Blocks: Reduces construction demolition waste.

Prime Application Scenarios

• Aggregate Production (Secondary/Tertiary): Producing final spec aggregates requiring high cubicity. Often follows a primary jaw crusher.
• Construction & Demolition (C&D) Waste Recycling: The most common application. Mobility allows processing directly on demolition sites. Handles variability in feed.
• Asphalt Recycling: Processing RAP for reuse in new asphalt mixes.
• Sand Manufacturing: Can produce manufactured sand, though often generates more fines than VSI crushers.
• Contract Crushing: Mobility is key for contractors moving between diverse jobs involving suitable materials.

When Purchasing a Track-Mounted Impact Crusher, Which Technical Parameters and Configurations are Crucial?

Crucial parameters include rotor diameter and width, maximum feed size, throughput capacity, engine power, CSS/apron adjustment range, transport weight/dimensions, and optional configurations like pre-screens, magnetic separators, and closed-circuit screens with return conveyors.

Essential Technical Specifications

• Rotor Dimensions (Diameter x Width): Larger rotors generally handle larger feed sizes and offer higher throughput potential. Width impacts capacity.
• Maximum Feed Size: Ensure the machine can accept the largest rocks you expect to feed it consistently. Consider the “effective” opening, not just the physical gap.
• Throughput Capacity (tph): Look for ratings specific to your material type (e.g., limestone vs. concrete). Be conservative; maximum ratings are under ideal conditions.
• Engine Power (kW/HP): Must be sufficient to handle the expected load without strain. Consider fuel efficiency and emissions standards. Electric options are increasingly available.
• Transport Weight & Dimensions: Critical for road permits and site accessibility. Ensure your transport equipment can handle it.

Important Configurations & Options

• Vibrating Feeder with Pre-Screen: Highly recommended. Removes fines before crushing, improving efficiency and reducing wear. Check screen size and type options.
• Magnetic Separator: Essential for recycling applications to remove steel rebar. Check magnet strength, position, and ease of cleaning.
• Closed-Circuit System: Includes an onboard screen and return conveyor to send oversized material back to the crusher. Produces a finished spec product in one unit. Optimize screen media and ensure the return system isn’t a bottleneck. The entire circuit needs to be balanced for efficient operation.
• Dust Suppression System: Water spray nozzles at feed, discharge, and transfer points to control dust. Increasingly required by regulations.
• Remote Control: For safe operation and easy repositioning.

Customer site

Track-mounted impact crushers are versatile tools for producing quality aggregates and recycling materials. ZONEDING MACHINE offers reliable, customizable solutions.