Producing construction-grade aggregate in the UAE requires three sequential and interdependent processes: primary crushing, secondary and tertiary crushing with screening, and washing. Each stage has a direct impact on the quality, gradation, and cleanliness of the finished product. This guide covers the complete aggregates processing chain using Terex MPS, Terex Washing, and Kleemann equipment — all available through Genavco, the authorised UAE distributor.
From Rock to Ready-Mix: Understanding the Aggregates Processing Chain
Aggregate production begins with a primary crusher reducing quarried rock to a manageable feed size. That material passes to secondary crushers — cone crushers or impact crushers — which reduce it further to specified gradations. Screening plants classify the crushed material by size. Where clean, washed aggregate is required for concrete, mortar, or asphalt production, a sand washing plant removes clay, silt, and fine contaminants to meet specification.
Terex MPS Cone Crusher - Consistent Cubicity & Fine Gradation
The Terex MPS cone crusher uses an eccentric crushing mechanism that produces aggregate with a consistently cubical particle shape — the geometry demanded by structural concrete and high-performance asphalt specifications. The closed-side setting is adjusted hydraulically, allowing operators to modify output gradation rapidly in response to changing product requirements without stopping production.
Cone Crusher: Secondary & Tertiary Crushing for High-Grade Aggregates
Cone crushers operate as secondary and tertiary crushing stages, receiving material pre-crushed by a jaw crusher and reducing it to finished aggregate sizes between 6mm and 40mm. Their high reduction ratio, combined with the ability to handle abrasive materials without rapid wear, makes them the preferred choice for hard rock quarries producing aggregate for structural concrete and wearing course asphalt.
Terex MPS Vertical Shaft Impactor - Manufactured Sand Production
The Terex MPS Vertical Shaft Impactor (VSI) is the standard solution for producing manufactured sand — fine aggregate with controlled particle shape to replace increasingly scarce natural sand. The VSI accelerates material through a high-speed rotor and impacts it against a rock shelf or metal anvils, producing a fine, well-graded product that meets the requirements of BS EN 12620 and ASTM C33.
Vertical Shaft Impactor (VSI): Superior Cubicity for Asphalt & Concrete
VSI-produced aggregate consistently outperforms cone-crushed material in shape index testing. For high-traffic asphalt wearing courses, where aggregate shape directly affects skid resistance and fatigue life, VSI-shaped aggregate is often specified by road authorities as a contractual requirement. The Terex MPS VSI delivers this performance consistently at production rates suited to large-scale quarry operations.
Terex MPS Screening Plant - Multi-Deck Scalping & Finishing
Terex MPS screening plants are available in single, double, and triple-deck configurations, allowing simultaneous separation of crushed material into multiple product sizes in a single pass. Modular screen media — polyurethane, woven wire, and perforated plate — can be configured to match the screening task, from coarse scalping ahead of secondary crushing to fine finishing screens for specification sand production.
Screening Plant: Classifying & Grading Crushed Material by Size
A screening plant is the quality control instrument of the aggregates process. It ensures that material passed to the next production stage or dispatched to customers meets the specified gradation. Undersized material is returned for further crushing. Oversized material is rejected or reprocessed. Without accurate screening, particle size distribution will be inconsistent and customer specifications cannot be guaranteed.
Terex Washing Aggwash - Combined Washing & Screening in One Unit
The Terex Washing Aggwash combines a washing and screening function in a single compact unit, making it ideal for quarries and recycling operations where space is limited. The Aggwash accepts both fine and coarse material simultaneously, washing and classifying in a single pass — reducing plant footprint, installation cost, and operational complexity.
Sand Washing Plant: Removing Contaminants for Clean, Graded Aggregates
A sand washing plant uses water and mechanical agitation to remove clay, silt, mica, and organic contaminants from fine aggregate. In the UAE, where local aggregate sources can carry elevated clay and salt content, washing is often not optional — it is a specification requirement for structural concrete, block paving, and cement-bound materials.
Terex Washing Hydrocyclone Plant - Fines Recovery & Water Recycling
Terex Washing's hydrocyclone plant recovers fine sand particles from process water using centrifugal separation — capturing material that would otherwise be lost to waste ponds. The recovered fine sand is a saleable product, and the clarified water is recycled back into the washing process, reducing fresh water consumption to a fraction of a conventional washing plant.
Terex MPS Cone & Impact Crushers: Secondary Crushing Excellence
The full Terex MPS secondary crushing range — including the Canica VSI, MPS cone, and MPS impact crusher series — covers every hard rock and recycled material application. All machines share a common parts platform, and Genavco maintains a UAE spare parts inventory for fast turnaround on high-wear items including manganese liners, blow bars, and screen media.
Kleemann Jaw Crusher - Primary Feed into the Secondary Stage
Kleemann jaw crushers provide the primary crushing stage that feeds the Terex MPS secondary circuit. The Kleemann MOBICAT series is available in both tracked mobile and stationary configurations, with jaw openings from 600mm to 1,100mm handling feed material directly from blasting or mechanical excavation.
Terex Washing Systems: Hydrocyclone & Coarse Washing Technology
The Terex Washing range extends beyond the Aggwash to include log washers for highly contaminated materials, coarse material washers, and complete integrated washing systems designed to process 50 to 500 tonnes per hour of mixed aggregate in a continuous, automated production line.
Kleemann Mobile Crushers: Primary Crushing Feeding the Circuit
Kleemann mobile jaw and impact crushers bring primary crushing capability directly to the quarry face, eliminating the need for separate material transport to a static plant. The tracked mobility of MOBICAT and MOBIREX machines allows rapid repositioning as the quarry face advances, reducing the haulage distance for excavated material significantly.
Crushing Circuit Design: Matching Primary, Secondary & Washing Stages
A correctly designed crushing circuit matches the throughput of primary, secondary, and washing stages so that no stage creates a bottleneck. Genavco's technical team has the application knowledge to design and specify complete circuits using Kleemann, Terex MPS, and Terex Washing equipment, ensuring the plant delivers the specified production rate from day one.
Water Management for Washing Operations: Settling & Recycling
Water management is a regulatory and operational priority for any quarry operating a washing plant in the UAE. Settling ponds, thickeners, and filter presses are used to recover solids from wash water, produce a dewatered cake for disposal, and recycle clarified water back into the process. Genavco can advise on water management systems compatible with Terex Washing plant specifications.
Frequently Asked Questions About Crushing, Screening & Washing
Can the Terex MPS cone crusher handle recycled concrete?
Yes — with appropriate liner selection, cone crushers process recycled concrete aggregate (RCA) effectively for secondary and tertiary crushing stages.
What water volumes does the Terex Washing Aggwash require?
Water consumption depends on feed contamination levels, but Terex Washing plants with hydrocyclone recycling typically operate at a fraction of conventional washing plant water usage.
Conclusion
From primary jaw crushing through secondary cone and VSI stages to washing and fine sand recovery, the combination of Kleemann, Terex MPS, and Terex Washing equipment covers the complete UAE aggregates processing requirement.
Contact Genavco to discuss your quarry or recycling application, request a plant layout proposal, or arrange a technical review of your existing crushing circuit.
