Case Studies of Successful Aggregate Washing – Part 1

Aggregate washing plays an important role in the production of high-quality construction materials, ensuring that aggregates meet strict specifications for various applications. However, it is far from a one-size-fits-all process, especially considering the various types of sand, diverse sources and deposits, and the range of washing equipment available. Because of this, what may work for one aggregate producer may not work for another.

In this blog series, we will highlight real-world examples of aggregate producers who have not only achieved but exceeded their goals with the addition or upgrade of Eagle Iron Works equipment.

Whether you’re looking to improve product quality, increase yield or modernize your washing operation, these case studies offer practical insights and proven strategies you can apply to your own plant. Use the links throughout the series to explore each story in more detail and see how the right solution can drive success.

Located in Grand Haven, Mich., S&M Gravel is a third-generation family-owned operation that has been actively producing sand and gravel since the early 1980s. After years of using EIW equipment manufactured in the 60s and 70s, they decided it was time for a plant upgrade to handle newly discovered usable reserves.

For the new wash plant, Maverick Environmental Equipment recommended an EIW Coarse Material Washer, an EIW CONDOR Single Fine Material Washer and an EIW CONDOR Double Fine Material Washer to be used in conjunction with other wet processing equipment. Because S&M Gravel’s products are used for construction and infrastructure products, it is important that the organics are removed so that they don’t hinder the aggregates’ performance. The EIW Fine Material Washers have been successfully washing and dewatering the fine aggregate products after the initial scrubbing by the EIW Coarse Material Washer.

The EIW equipment is proving to be an efficient and consistent way for S&M Gravel to produce clean aggregates. The equipment paired with the service and support of their EIW dealer has been a reliable solution for their operation.

Operating a 26-year-old Eagle wash plant in De Steeg, Netherlands, a sand and gravel producer continues to see the benefits of EIW's long-lasting Fine Material Washer gear reducer. With a history dating back to 1996, the plant utilizes EIW equipment, including a 40’x10’ Classifying Tank and two 66”x35’ Single Screw Fine Material Washers, to classify and dewater minus 4mm material at a 400 tph feed rate.

After processing over 25 million tons of concrete sand over the years, the plant encountered wear in various components, prompting the need for replacements. However, the gears in the reducer were still operating smoothly. Because of their trust in Eagle equipment, the producer approached Syscom BV Industrial Equipment to replace the worn elements, while still utilizing the existing gear reducer. By replacing elements of the old Fine Material Washer and keeping the existing gear reducer, the customer achieved substantial cost savings while ensuring continued reliable performance for decades to come.

This success shows EIW's commitment to robust, heavy-duty equipment, earning the brand a reputation for long-lasting service across the aggregate industry.

Precision Aggregate Products, LLC, a leading provider of construction aggregates in Mesquite, Nev., sought to enhance their production capabilities to meet the growing demands of the local market. Despite enjoying over a decade of smooth operation with their Eagle Fine Material Washer, Precision Aggregate recognized the need to increase output.

With a proven track record and a strong partnership with Eagle Iron Works and their Nevada dealer, ICM Solutions, Precision Aggregate opted for an Eagle CONDOR 44” double screw Fine Material Washer. The CONDOR's classic EIW features, coupled with an industry-recognized Dodge TA II gear reducer, ensured reliability and ease of maintenance. This upgrade doubled their production capacity, enabling them to meet customer needs efficiently.

Precision Aggregate praises Eagle's incomparable support and service, emphasizing their commitment to delivering high-quality, reliable equipment that is ready to perform day in and day out. Despite the upgrade, Precision Aggregate plans to reintegrate their Eagle single screw in the future, underscoring their confidence in Eagle's reliability and performance.

These case studies highlight how the right aggregate washing solution can transform operational challenges into measurable results. By addressing material-specific issues and production goals, these producers were able to improve product quality, increase efficiency, and maximize material recovery. Explore the full case studies linked above to see the complete process, equipment selection, and performance outcomes in detail.