Cant believe i got two pages out of this but panic over i think ive tracked down part of the answer
The Manufacturing
Process
The preparation of sand consists of five basic processes: natural decomposition, extraction, sorting, washing, and in some cases crushing. The first process, natural decomposition, usually takes millions of years. The other processes take considerably less time.
The processing plant is located in the immediate vicinity of the natural deposit of material to minimize the costs of transportation. If the plant is located next to a sand dune or beach, the plant may process only sand. If it is located next to a riverbed, it will usually process both sand and gravel because the two materials are often intermixed. Most plants are stationary and may operate in the same location for decades. Some plants are mobile and can be broken into separate components to be towed to the quarry site. Mobile plants are used for remote construction projects, where there are not any stationary plants nearby.
The capacity of the processing plant is measured in tons per hour output of finished product. Stationary plants can produce several thousand tons per hour. Mobile plants are smaller and their output is usually in the range of 50-500 tons (50.8-508 metric tons) per hour.
In many locations, an asphalt production plant or a ready mixed concrete plant operates on the same site as the sand and gravel plant. In those cases, much of the sand and gravel output is conveyed directly into stockpiles for the asphalt and concrete plants.
The following steps are commonly used to process sand and gravel for construction purposes.
Natural decomposition
* Solid rock is broken down into chunks by natural mechanical forces such as the movement of glaciers, the expansion of water in cracks during freezing, and the impacts of rocks falling on each other.
* The chunks of rock are further broken down into grains by the chemical action of vegetation and rain combined with mechanical impacts as the progressively smaller particles are carried and worn by wind and water.
* As the grains of rock are carried into waterways, some are deposited along the bank, while others eventually reach the sea, where they may join with fragments of coral or shells to form beaches. Wind-borne sand may form dunes.
Extraction
* Extraction of sand can be as simple as scooping it up from the riverbank with a rubber-tired vehicle called a front loader. Some sand is excavated from under water using floating dredges. These dredges have a long boom with a rotating cutter head to loosen the sand deposits and a suction pipe to suck up the sand.
* If the sand is extracted with a front loader, it is then dumped into a truck or train, or placed onto a conveyor belt for transportation to the nearby processing plant. If the sand is extracted from underwater with a dredge, the slurry of sand and water is pumped through a pipeline to the plant.
Sorting
* In the processing plant, the incoming material is first mixed with water, if it is not already mixed as part of a slurry, and is discharged through a large perforated screen in the feeder to separate out rocks, lumps of clay, sticks, and other foreign material. If the material is heavily bound together with clay or soil, it may then pass through a blade mill which breaks it up into smaller chunks.
* The material then pass through several / perforated screens or plates with different hole diameters or openings to separate the particles according to size. The screens or plates measure up to 10 ft (3.1 m) wide by up to 28 ft (8.5 m) long and are tilted at an angle of about 20-45 degrees from the horizontal. They are vibrated to allow the trapped material on each level to work its way off the end of the screen and onto separate conveyor belts. The coarsest screen, with the largest holes, is on top, and the screens underneath have progressively smaller holes.
Washing
* The material that comes off the coarsest screen is washed in a log washer before it is further screened. The name for this piece of equipment comes from the early practice of putting short lengths of wood logs inside a rotating drum filled with sand and gravel to add to the scrubbing action. A modern log washer consists of a slightly inclined horizontal trough with slowly rotating blades attached to a shaft that runs down the axis of the trough. The blades churn through the material as it passes through the trough to strip away any remaining clay or soft soil. The larger gravel particles are separated out and screened into different sizes, while any smaller sand particles that had been attached to the gravel may be carried back and added to the flow of incoming material.
* The material that comes off the intermediate screen(s) may be stored and blended with either the coarser gravel or the finer sand to make various aggregate mixes.
* The water and material that pass through the finest screen is pumped into a horizontal sand classifying tank. As the mixture flows from one end of the tank to the other, the sand sinks to the bottom where it is trapped in a series of bins. The larger, heavier sand particles drop out first, followed by the progressively smaller sand particles, while the lighter silt particles are carried off in the flow of water. The water and silt are then pumped out of the classifying tank and through a clarifier where the silt settles to the bottom and is removed. The clear water is recirculated to the feeder to be used again.
* The sand is removed from the bins in the bottom of the classifying tank with rotating dewatering screws that slowly move the sand up the inside of an inclined cylinder. The differently sized sands are then washed again to remove any remaining silt and are transported by conveyor belts to stockpiles for storage.
Crushing
* Some sand is crushed to produce a specific size or shape that is not available naturally. The crusher may be a rotating cone type in which the sand falls between an upper rotating cone and a lower fixed cone that are separated by a very small distance. Any particles larger than this separation distance are crushed between the heavy metal cones, and the resulting particles fall out the bottom.