Selecting a sand screen starts with the material entering the system and the fractions required by the mortar formulation. Equipment appearance, deck count or a nominal capacity figure cannot establish whether a proposed arrangement will meet those requirements.
For a mortar manufacturer, the objective is a reliable supply of suitable sand fractions for batching. A useful specification connects feed characteristics, separation performance, output demand and plant integration.
Illustrative vibrating screen configuration. Final selection depends on the material and separation duty.
1. Define the separation task
First, establish whether the screen will remove oversize particles from otherwise suitable sand or separate several fractions for controlled blending.
These duties have different requirements. State the target size ranges, how many separate products are needed and where each stream will go. Also identify whether the finest fraction will be retained, reprocessed or rejected according to the formulation.
Do not apply one set of cut sizes to every mortar product. The specification should follow the requirements of the intended formulations.
2. Describe the feed beyond its maximum size
Provide representative sieve-analysis results showing the proportions within relevant size ranges. Two sands with the same maximum particle size can contain very different amounts of fine material and material close to the intended separation sizes.
Also report the sand source, moisture range, temperature, bulk density and any tendency to clump. Record whether the screen receives wet sand, washed material or dried sand from an upstream process.
These conditions help determine equipment sizing, screen media and whether cleaning arrangements or material conditioning require evaluation. Use samples representing expected supply variation rather than selecting only the easiest material to screen.
3. Separate feed capacity from fraction output
Total screening throughput does not equal the output of every individual fraction.
Consider an illustrative dry-material balance:
| Item | Example |
|---|---|
| Total dry feed | 20 t/h |
| Target-size material in the feed | 25% by mass |
| Target-size material entering the screen | 5 t/h |
This calculation describes the target-size material available before separation. It is not a guaranteed product-output figure. Actual recovery and the amount of misplaced material must be checked.
If production requires more than 5 t/h of correctly sized material in that range, this feed cannot supply it at 20 t/h without changes to the material balance. Increasing the screen size alone cannot create the missing particles.
Specify total feed rate and demand for each fraction on a consistent moisture basis. Include normal operating rates, expected surges and the production schedule.
4. Define how the result will be accepted
Screen aperture is an equipment parameter; the discharged material still requires verification.
For each product stream, define the required size range and permitted oversize and undersize content. Agree on the sampling procedure, test method and operating conditions used for assessment.
Samples should represent the relevant discharge stream and operating period. A single favourable sample does not describe performance across changing feed conditions.
Where appropriate, use trials with representative sand to assess separation quality, recovery and achievable throughput before finalising the configuration. Retain the trial conditions and results so comparisons use the same basis.
5. Check integration and maintenance requirements
Confirm how material will be presented to the screen and how each discharge stream will reach its destination. Feeding consistency, separate transfer routes and storage interfaces should support the intended batching arrangement.
Provide available headroom, installation dimensions, support information and access requirements. Discuss dust extraction and suitable sealing at feed and discharge connections.
Allow access for inspection, cleaning and screen-media replacement. Selection should account for routine maintenance as well as installation.
Prepare a useful screening enquiry
Bring together the target mortar products, representative feed analysis, moisture and temperature ranges, total feed rate, required fractions, acceptance criteria and site layout.
Purchased sand may need only a limited screening duty; another source may require a more extensive preparation route. The final configuration should follow the measured material condition and production requirements.
Planning a new system or upgrading an existing line? Share your sand data, target fractions, required output and project location with CHANGYU INDUSTRIAL to discuss the screening configuration.