Impact Crusher

Product Introduction

What Is an Impact Crusher?

An Impact Crusher is a crushing machine that uses high-speed impact force to reduce rock, minerals, concrete and other materials into smaller, more uniformly shaped particles.

In a horizontal shaft impactor, also known as an HSI Crusher, the feed material enters the crushing chamber and is struck by blow bars mounted on a rapidly rotating rotor. The material is accelerated toward the impact aprons and breaker plates, where repeated impact and particle-to-particle collision complete the crushing process.

Impact crushers are commonly used for:

• Primary crushing of selected soft and non-abrasive rock
• Secondary crushing in quarry plants
• Aggregate shaping
• Limestone processing
• Cement raw material preparation
• Concrete and demolition waste recycling
• Asphalt recycling
• Mobile contractor crushing

Sandvik describes stationary HSI crushers as suitable for primary or secondary crushing of materials such as limestone, recycled material and cement-industry feed, with high reduction ratios and hydraulic adjustment features.

Typical Applications

Quarry Aggregate Production

The impact crusher is particularly suitable for producing aggregates with a cubical shape and controlled gradation.

Typical finished products include:

• Concrete aggregate
• Asphalt aggregate
• Road base material
• Railway ballast feed
• Manufactured sand feed
• Commercial graded stone

Limestone Crushing

A limestone impact crusher can achieve a high reduction ratio and may reduce the number of crushing stages required in suitable applications.

It is widely used in:

• Limestone quarries
• Cement plants
• Lime production plants
• Aggregate processing facilities

Construction Waste Recycling

A mobile impact crusher can process:

• Demolished concrete
• Concrete blocks
• Bricks
• Asphalt pavement
• Mixed construction waste
• Reinforced concrete after suitable pre-processing

Mining and Industrial Minerals

Depending on feed hardness and abrasiveness, impact crushers can also process:

• Coal
• Gypsum
• Dolomite
• Phosphate rock
• Salt
• Clay
• Soft ore
• Industrial mineral feed

Suitable Materials

Recommended Materials

• Limestone
• Dolomite
• Gypsum
• Coal
• Concrete
• Asphalt
• Brick
• Construction Waste
• Soft Rock
• Medium-Hard Rock
• Selected Non-Abrasive Ore

Material Selection Notice

Impact crushers are generally more suitable for soft to medium-hard materials with low to moderate abrasiveness.

For highly abrasive hard rock such as quartz-rich granite, basalt or certain iron ores, the wear cost of blow bars and impact liners must be evaluated carefully. In many such applications, a cone crusher may provide lower wear cost, while the impact crusher may still be used where superior particle shape is the main priority.

Main Advantages

High Reduction Ratio

The high-speed rotor and multi-stage impact chamber allow significant size reduction in one crushing stage.

Cubical Product Shape

Impact crushing produces more cubical particles with fewer elongated and flaky pieces, making it suitable for concrete and asphalt aggregate production.

Large Feed Opening

A wide feed opening accepts relatively large material and supports stable continuous feeding.

Adjustable Final Product Size

The apron gap, rotor speed and crusher configuration can be adjusted to control product gradation and fines production.

Hydraulic Adjustment

Hydraulic systems simplify apron adjustment, chamber opening and routine maintenance.

Easy Wear Parts Replacement

The crusher housing can be opened to provide access to blow bars, impact plates and side liners.

Flexible Installation

Available configurations include:

• Stationary Impact Crusher
• Mobile Impact Crusher
• Tracked Impact Crusher
• Wheeled Impact Crusher
• Open-Circuit Crusher
• Closed-Circuit Crushing Plant

Suitable for Recycling

The high reduction ratio and strong impact action make the equipment effective for concrete, asphalt and demolition waste recycling.

Working Principle

The motor drives the rotor through a belt transmission system.

When the material enters the crushing chamber, the high-speed blow bars strike and accelerate it toward the impact aprons. The material is crushed by:

1. Direct impact from the blow bars
2. Collision with the impact aprons
3. Particle-to-particle impact
4. Repeated circulation inside the crushing chamber

Once the particles become smaller than the adjusted discharge gap, they leave the bottom of the crusher.

Main Components

The HSI impact crusher mainly consists of:

• Feed Hopper
• Crusher Housing
• Heavy-Duty Rotor
• Blow Bars
• Rotor Shaft
• Bearings
• First Impact Apron
• Second Impact Apron
• Breaker Plates
• Side Liners
• Hydraulic Cylinders
• Drive Pulley
• Electric Motor
• Belt Guard
• Lubrication System
• Safety Protection System

Technical Specifications

The listed capacities are indicative only. Actual production depends on feed gradation, bulk density, moisture content, material abrasiveness, rotor speed, apron setting and required final product size.

Available Crusher Types

Stationary HSI Impact Crusher

For fixed quarry, mining, cement and aggregate processing plants.

Primary Impact Crusher

Designed with a large feed opening and heavy rotor for selected soft or non-abrasive rock.

Secondary Impact Crusher

Installed after a jaw crusher to produce smaller and better-shaped aggregate.

Mobile Impact Crusher

Mounted on a tracked or wheeled chassis for quarry contractors, recycling sites and short-term projects.

Reversible Impact Crusher

Uses reversible rotor operation in selected applications to improve wear utilization.

Closed-Circuit Impact Crusher

Combined with a vibrating screen and return conveyor to produce accurately sized finished products.

Crusher Wear Parts

We supply complete impact crusher wear parts and replacement components.

Main Wear Parts

• Blow Bars
• Impact Plates
• Breaker Plates
• Impact Apron Liners
• Side Liners
• Rotor Protection Plates
• Wear Plates
• Feed Chute Liners
• Wedges
• Blow Bar Locking Devices
• Curtain Liners

Blow Bar Materials

High Chrome Blow Bars

Suitable for:

• Limestone
• Concrete without excessive steel
• Highly abrasive but lower-impact feed
• Fine crushing applications

Martensitic Steel Blow Bars

Suitable for:

• Recycling
• Medium-abrasive material
• Applications requiring a balance of toughness and wear resistance

Martensitic Steel with Ceramic Inserts

Suitable for:

• Longer wear-life applications
• Medium to high abrasiveness
• Controlled feed conditions

High Manganese Steel Blow Bars

Suitable for:

• Large feed
• High-impact conditions
• Lower-abrasiveness materials
• Applications requiring high toughness

Chrome Ceramic Blow Bars

Suitable for:

• High wear resistance
• Selected quarry applications
• Stable feed without excessive tramp metal

Blow-bar selection should be based on material hardness, silica content, feed size, impact load, tramp-metal risk and required product size—not simply on which alloy has the highest nominal hardness.

Aftermarket Replacement Parts

We can manufacture aftermarket crusher wear parts according to:

• Part Number
• Machine Model
• Original Drawing
• Customer Drawing
• Worn Sample
• 3D Scanning Data
• Chemical Composition Requirement
• Working Conditions

Available for selected models from major international crusher manufacturers.

Optional Configurations

• Hydraulic Apron Adjustment
• Hydraulic Housing Opening
• Variable-Speed Drive
• Vibration Monitoring
• Bearing Temperature Monitoring
• Automatic Lubrication System
• Electric Motor Drive
• Diesel-Hydraulic Drive
• Mobile Track Chassis
• Pre-Screening Feeder
• Magnetic Separator
• On-Board Vibrating Screen
• Return Conveyor
• Dust Suppression System
• Maintenance Crane
• Blow Bar Lifting Device

Recommended Plant Configurations

Limestone Aggregate Plant

Vibrating Feeder
↓
Primary Jaw Crusher
↓
Secondary Impact Crusher
↓
Vibrating Screen
↓
Finished Aggregates

Soft-Rock Two-Stage Plant

Vibrating Feeder
↓
Primary HSI Impact Crusher
↓
Vibrating Screen
↓
Finished Products

Construction Waste Recycling Plant

Feeding Hopper
↓
Pre-Screen
↓
Mobile Impact Crusher
↓
Magnetic Separator
↓
On-Board Screen
↓
Recycled Aggregate

Closed-Circuit Mobile Plant

Tracked Impact Crusher
↓
Double-Deck Screen
↓
Qualified Product
+
Oversize Return to Crusher

Installation Requirements

Packaging and Shipping

Available packing methods:

• Export Steel Frame
• Protective Film
• Wooden Cases for Components
• Moisture-Proof Packing
• Container Loading
• Flat Rack Shipping
• Break-Bulk Shipping

Wear parts are normally packed separately in reinforced wooden cases or steel pallets.

FAQ

Q1. What is an HSI impact crusher?

An HSI crusher is a horizontal shaft impactor that uses a high-speed horizontal rotor and blow bars to crush material against impact aprons.

Q2. Is an impact crusher suitable for primary crushing?

Yes. Heavy-duty primary impact crushers can process selected soft and non-abrasive materials with large feed sizes. For hard or highly abrasive rock, a jaw crusher is often preferred for primary crushing.

Q3. What materials can an impact crusher process?

It is commonly used for limestone, dolomite, gypsum, coal, concrete, asphalt, construction waste and other soft to medium-hard materials.

Q4. What is the difference between an impact crusher and a cone crusher?

An impact crusher breaks material through high-speed impact and normally produces a more cubical shape. A cone crusher uses compression and is generally better suited to hard, abrasive rock with lower wear cost.

Q5. What controls the final product size?

The final gradation is influenced by:

• Rotor speed
• Blow-bar configuration
• Impact-apron gap
• Feed size distribution
• Material properties
• Closed-circuit screening

Q6. Can the crusher process reinforced concrete?

Yes, provided suitable feeding, pre-processing and metal-removal systems are used. A magnetic separator is recommended for removing exposed steel.

Q7. How do I select the correct blow-bar material?

Selection depends on feed hardness, abrasiveness, maximum lump size, impact load, tramp-metal risk and operating conditions.

Q8. Can you provide mobile impact crushers?

Yes. Tracked and wheeled mobile configurations can be supplied with feeders, pre-screens, magnetic separators, vibrating screens and return conveyors.

Q9. Do you provide crusher wear parts?

Yes. Blow bars, impact plates, side liners, breaker plates, rotor protection parts and other replacement components are available.

Q10. Can you design a complete crushing plant?

Yes. The crushing and screening system can be configured according to the raw material, capacity, feed size, final product specification and site conditions.

RFQ / Inquiry Information

Tell Us About Your Crushing Project

1. What material will be crushed?
2. What is the maximum feed size?
3. What final product sizes are required?
4. What capacity is required in TPH?
5. What is the approximate silica content or abrasiveness?
6. Is the material dry, wet or sticky?
7. Is the crusher for primary or secondary crushing?
8. Do you need a stationary, tracked or wheeled machine?
9. Is reinforced concrete or tramp metal present?
10. What voltage and frequency are available on site?
11. Which country will the equipment operate in?
12. Do you also require blow bars and other wear parts?