Urban expansion generates large-volume demolition debris. Jaw crushers and impact crushers represent the mainstream process solution for producing qualified recycled aggregates in concrete-recycling projects.
For concrete mixed with hard materials such as granite and basalt, scattered-site recycling or large-scale construction waste landfills, cone crushers and mobile crushers can be flexibly incorporated.
The complete crushing-recycling workflow follows:
Primary Crushing (Jaw Crusher) → Iron Removal (Iron Remover) → Secondary & Tertiary Crushing (Impact Crusher) → Screening (Vibrating Screen)
Recycled coarse aggregates and recycled fine aggregates are produced for applications including road subbases, permeable bricks and commercial recycled concrete.
Jaw crusher: primary crushing for concrete recycling
Waste-concrete feedstock mostly comes in large lumps, some embedded with rebar.
The jaw crusher conducts primary crushing via compression force, reducing large concrete blocks into feed suitable for secondary-stage crushers.
- Capacity: 5–10 t/h, 10–50 t/h, 50–150 t/h, 150–500 t/h
- Reduction ratio: 4:1–8:1
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This unit handles high-load feed of rebar-reinforced concrete with long-service-life manganese-steel jaw plates, cutting downtime for maintenance.
Key advantages:
- High material adaptability: processes mixed impurities including concrete, bricks, tiles and small amounts of sand-soil.
- Stable operation: responsive tramp-iron protection safeguards the machine against rebar damage, preventing blockages, equipment failure and financial losses caused by shutdowns.
- Compared with most crushers on the market: more wear-resistant spare parts, higher energy efficiency at equal throughput, robust heavy-duty design. With proper maintenance, service life reaches 8–15 years.
Impact crusher: secondary crushing & aggregate shaping
Material pre-crushed by the jaw crusher feeds into the impact crusher for fine crushing and shaping via high-speed impact force.
Impact crushers produce aggregates with a high cubic-fraction ratio and minimal flaky particles. High-velocity impact strips aged cement mortar adhered to stone surfaces to improve recycled-aggregate quality.
End-products meet specifications for road sub-bases and recycled building-material applications.
Main Product Specifications:
- Capacity: 10–30 t/h, 50–150 t/h, 70–180 t/h, 180–800 t/h
- Reduction ratio: 10:1–20:1
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Under closed-circuit operation, impact crushers can achieve a finished-product qualification rate of 92–98%. Superior particle shape enables higher market resale value for discharged material.
Important Note: A suspension permanent magnet iron remover should be installed between the jaw crusher and impact crusher. It removes embedded rebar and ferrous fragments from concrete feed in advance. This protects blow bars from heavy wear and prevents blockage failures.
After classification by vibrating screens, recycled aggregates of different sizes serve distinct market applications:
- 0–5 mm: Mainly for brick-making, mortar and backfill. High fines content; powder proportion requires strict control during application.
- 5–20 mm: Highest-profit output for recycling projects, used for permeable building materials and non-structural recycled concrete.
- 20–40 mm: Primarily for road sub-base construction. High output volume with lower unit selling price.
When recycled feed contains abundant hard rock lumps, a simple jaw-plus-impact-crusher setup leads to drastically accelerated wear on impact-crusher blow bars.
Cone crushers excel at high-hardness material processing with far lower wear-part consumption than impact crushers. Their downside is inferior particle shape compared with impact crushers.
For such conditions, a cone crusher can be configured after the jaw crusher.
Situations requiring a cone crusher:
- Recycling projects for construction waste mixed with granite, basalt, diabase and hard old concrete riprap units.
- Large-scale stationary construction-waste landfills with unknown feed-material sources.
Mobile jaw & impact crushers: on-site recycling solution
Mobile crushing stations match stationary crushing equipment in capacity, feed-discharge size, wear-part service life and operational stability.
For short-term schedules, multiple projects and no wish to build permanent plant facilities, tracked-type or wheel-type mobile crushing stations are the economically recommended option.
The complete unit integrates feeding, crushing and screening modules and can drive directly into demolition job sites.
- Mobile jaw crusher: Handles on-site primary crushing, paired with an onboard iron remover for rebar removal.
- Mobile impact crusher: Follows to perform fine crushing and aggregate shaping of concrete.
Likewise, you may select a mobile cone crusher to process hard materials within concrete. A dust-removal module is also available to meet urban-site environmental dust-control requirements.
Overall, the advantages of mobile crushers for concrete recycling are reflected in the following aspects:
- Higher flexibility: Self-propelled design enables multiple site relocations within one month.
- Smaller footprint: Hydraulically foldable, compact layout for limited urban working spaces.
- Fast commissioning: No concrete foundation required; production starts within 1–3 days. No dismantling work after project completion.
- Lower freight & labor cost: On-site crushing eliminates back-and-forth material haulage. Integrated intelligent control simplifies operation and maintenance.
- Reliable operation: Supports both diesel-powered and grid power supply; stable startup even under extreme cold (-10 °C).
- Road-transport friendly: Our experienced engineering team delivers optimized weight-reduction design. Repeated testing and real-project validation guarantee stable performance and production capacity while reducing overall machine weight.
| Parameter | Mobile Jaw Crusher | Mobile Impact Crusher | Mobile Cone Crusher |
| Feed Size | 480–800 mm | 350–700 mm | 280–360 mm |
| Capacity (t/h) | 70–350 t/h | 60–300 t/h | 80–250 t/h |
| Discharge Size | 80–250 mm | 0–80 mm | 0–60 mm |
Concrete recycling recommended solutions
- Ordinary waste concrete: Jaw crusher + iron remover + Impact crusher
- High-hardness, complex mixed concrete with unknown sources: Jaw crusher + Iron remover + Cone crusher + Impact crusher
- On-site construction operation: Adopt mobile jaw crusher and mobile impact crusher; equip with mobile cone crusher for harder materials.
Production line configuration is highly flexible. A hybrid combination of stationary and mobile crushing systems is applicable:
Mobile jaw crushing station (primary crushing + on-site iron removal) → Semi-finished material truck transportation → Stationary crushing line (cone crusher or impact crusher) → High-quality recycled aggregates.
All solutions are customized according to actual project requirements and site conditions, to deliver the most suitable and cost-effective crushing equipment for every client.
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Simply submit your project requirements, and FTM's seasoned professional engineering team delivers full-cycle support including:
- Project estimation: Calculate actual output, discharge size, equipment power consumption, wear parts, service life and production cycle based on your requirements.
- Solution design: Custom process flow design according to on-site condition evaluation.
- Logistics service: Modular container transportation to reduce costs and accelerate project startup. Transparent FOB and CIF pricing throughout the whole process.
- Factory inspection & testing: Factory pre-delivery testing, export packaging and sea freight arrangement.
- Installation & commissioning: Overseas on-site installation guidance and full machine commissioning.
- Document delivery: Complete handover of spare parts list, operation & maintenance manuals and warranty documents.
Full-process transparent services help you obtain cost-effective equipment and premium beyond-price support to strengthen your market competitiveness. Click for factory quotes & start your business
