Railway ballast is a vital component of the track structure, directly impacting track stability, drainage performance, and train safety. High-quality ballast must meet stringent requirements for particle size distribution, hardness, angularity, and cleanliness.
How can you choose the right crushing equipment to build an efficient and stable ballast production line? This article will provide an in-depth analysis of railway ballast production standards, key equipment selection, and key quality control points, helping you create ballast products that meet international standards. I. Core Standards for Railway Ballast
Based on customer specifications, high-quality railway ballast must meet the following key indicators:
✔ Particle Size Classification Requirements:
• Particles >63mm: 0% (complete rejection)
• Particles 51-63mm: ≤10%
• Particles 25-51mm: ≥90% (core range)
• Particles <19mm: ≥98% (ensuring fine particles meet standards)
✔ Physical Property Requirements:
• High hardness (compressive strength ≥150 MPa)
• High angularity (sharp particle edges for enhanced bite)
• Low abrasion (Los Angeles abrasion ≤20%)
• Absence of impurities (no organic or inorganic contaminants)
These standards dictate that the ballast crushing line must utilize a multi-stage crushing + fine screening + shaping optimization process.
2. Core Equipment Selection for Ballast Crushing Production Lines
1. Primary Crushing: Jaw Crusher
• Function: Coarse crushing of large lumps of rock, processing capacity 200-800 t/h
• Key Parameters: Feed size ≤ 800 mm, adjustable discharge opening 50-150 mm
• Advantages: Sturdy structure, suitable for crushing high-hardness rocks
2. Secondary Crushing: Cone Crusher
• Function: Secondary crushing stage, ensuring the maximum proportion of 25-51 mm particles
• Recommended Model: HP300 or higher, closed-side adjustable discharge opening 25-51 mm
• Advantages: Layered crushing, reducing over-crushing and increasing yield
3. Shaping Crushing: Vertical Shaft Impact Crusher (Sand Making Machine)
• Function: Enhances particle angle and optimizes particle shape
• Crushing method: Rock-on-rock or rock-on-iron, crushing ratio 1:3
Advantages: Finished product angularity index ≥ 0.6 (EN 13450 standard)
4. Screening System: Multi-layer vibrating screen
• Upper screen (63mm bar screen): Removes oversized particles
• Middle screen (51mm polyurethane screen): Controls the proportion of coarse particles
• Bottom screen (25mm + 19mm composite screen): Ensures that fine particles meet standards
• Screening efficiency: ≥ 95%, processing capacity ≥ 50t/h·m²
5. Purification System
• Electromagnetic iron remover (magnetic field strength ≥ 12000 GS) removes metallic impurities
• Air separation system (wind speed 8-12m/s) separates light debris
• Water washing system (water consumption ≤ 3m³/ton) improves cleanliness
III. Production Line Process Optimization
1. Closed-loop design
• Unqualified particles (e.g., > 63mm or < 19mm) are returned to the crusher for reprocessing
Improve yield and reduce waste.
2. Automated Control System
• PLC Intelligent Control: Real-time monitoring of particle size and moisture content, automatically adjusting the crusher discharge opening (accuracy ±1mm)
• Laser Particle Size Analyzer: Measures every 30 seconds to ensure a stable particle size
3. Environmental Protection Measures
• Dust Removal System (Emission Concentration ≤ 20mg/m³)
• Noise Reduction Module (Factory Boundary Noise ≤ 65dB)
IV. Quality Control and Performance Indicators
| Indicators | Standards | Test Methods |
| Particle Size Qualification Rate | ≥99.2% | Square Hole Screening |
| Angularity Index | ≥0.6 | EN 13450 |
| Flake Content | ≤15% | Aspect Ratio |
| Abrasion Value | ≤20% | Los Angeles Abrasion Test |
| Specific Energy Consumption | ≤2.8kWh/ton | Power Consumption Monitoring |
The quality of railway ballast directly impacts railway safety and service life. Through a multi-stage crushing + fine screening + shaping optimization process, coupled with an intelligent control system and rigorous quality inspections, we can produce high-quality ballast that fully meets international standards.
If you are planning a ballast production line, we recommend customizing the solution based on the parent rock characteristics (e.g., granite, basalt, etc.) and production capacity requirements (e.g., 100-500 tons per hour) to ensure equipment compatibility and long-term stable operation.
Baichy Heavy Industry – Your Trusted Partner for Seamless Equipment Operation
To ensure optimal performance of your equipment, Baichy Heavy Industry offers:
- Professional on-site installation guidance
- Comprehensive operator training
- 24/7 technical support & maintenance services
Our complete after-sales service system guarantees long-term, stable operation of your machinery with minimal downtime.
Protect Your Rights – Only Use Official Channels
To avoid scams and ensure authentic support, contact us exclusively through:
• Official Website: www.baichychina.com
• WhatsApp: +8615093222637
• Email: [email protected]
Your satisfaction is our priority – expect prompt, professional service every time.
(Note: Beware of unauthorized third parties claiming to represent Baichy. Always verify through official contacts.)
