gray crushed paving stones used for a diveway

Crushing stone is a straightforward process when you have the right equipment. Whether you're a contractor looking to repurpose on-site materials or a business aiming to produce aggregate for resale, understanding the basics of stone crushing can open up new revenue streams and reduce waste.

Are you tired of hauling piles of waste stone to the landfill? It might be time to consider turning those piles into a new revenue for you and your business. Crushed stone is in demand as it has so many uses. Depending on the size and type of crushed stone, different industries have different needs. These range from clean stone used as top layers of driveways all the way to road base in paving projects.

How to crush large rocks into smaller stones

To crush stone, you will firstly need a constant supply of large rocks. You might already be lucky and have loads at your job site! Some common rock examples are granite, caliche, and limestone. Small batches of soft rocks such as sandstone and caliche can be roughly broken up by a hydraulic breaker attached to an excavator. If the rocks are harder (granite and basalt) they will require more crushing power. A compact jaw crusher will be necessary for this job. If your goal is to crush natural stone, consider investing in a larger mobile jaw crusher as these will give you a lot more crushing power to break down that hard rock.

Omega j1065t crushing stone
Crushers can break down stone

What types of stone can you crush?

Stones come in a range of ‘hardnesses’ meaning some stones are harder than others. Hard rocks like granite have a stronger structure and are harder to break up - just think of how strong diamond is! Hard rock is great for building materials as it is very durable but in crushing this means that they will need a lot more energy and power to break them down. Soft stone like sandstone and limestone is crushed a lot more easily.

Stones vary in hardness, which affects how they should be crushed:

  • Soft Rocks: Such as limestone and sandstone, are easier to crush and can often be processed with smaller, less powerful equipment.
  • Hard Rocks: Like granite and basalt, require more force and are best handled with heavy-duty machinery.

A general rule: if the rock is harder than concrete or can't be scratched with a fingernail, it's considered hard and will need more robust crushing equipment.

table comparing the different kinds of rocks and their harness
Types of rocks and their hardness

Equipment for Crushing Stone

Selecting the right equipment is crucial:

  • Jaw Crushers: Ideal for primary crushing of hard materials. They use compressive force to break down large rocks.
  • Impact Crushers: Suitable for secondary crushing and producing well-shaped, cubical aggregates. They use high-speed impact to fracture materials.
  • Hydraulic Breakers: Useful for breaking up soft rocks or concrete before feeding them into crushers.

For example, the Omega J1065T is a heavy-duty jaw crusher suitable for hard rock, while the Terex Bison 120 is perfect for softer materials.

Do I need a screener to process crushed stone?

After crushing, it's essential to separate the material into different sizes using a screener. This process ensures that each size category—large stones, medium stones, small stones, and stone dust—is sorted for specific applications. For instance, the Barford 750J Jaw Crusher paired with a Barford 3-Way Screener can efficiently crush and sort materials on-site. At that point, the stones you have made can be used on your projects or sold to the public.

screener on site being used to separate stone into three piles of different sizes
Screener separating different sized stone

What can crushed stone be used for?

Crushed stone has many uses and is an excellent way to recycle excess rock waste that would otherwise be headed for the landfill. There is a high demand for crushed stone across many industries making it very popular with contractors.

Crushed stone is versatile and widely used in various industries:

  • Construction: As a base material for roads, driveways, and foundations.
  • Landscaping: For decorative purposes, pathways, and garden beds.
  • Agriculture: Improving soil drainage and as a component in fertilizers.
  • Erosion Control: Preventing soil erosion along waterways and embankments.

Here are a few ways crushed stone can be used in the construction and landscaping industries.

  • To smooth and level roads under the pavement
  • Enhance soil to improve crop growing conditions
  • Stone fill to support pipes and drainage beds
  • Protect roofing and reduce the heat from the sun
  • Prevent ice and water erosion when building bridges
  • As a buffer layer between concrete and soil
  • Decorative purposes in landscaping

Since crushed stone can be left as chunky rocks or crushed as fine as sand, it is multipurpose and in high demand across nearly all areas of construction.

Crushed stone driveway
Crushed stone driveway

What equipment should I use to crush rock?

Different machines are used for different hardnesses of stone. The smaller jaw crushers will not be able to cope with large amounts of hard stone as they will cause a lot of wear-and-tear on the jaw plates. This would mean they would need regular maintenance and replacement. If you want to crush lots of hard rock you would need a heavy-duty machine such as the Omega J1065T jaw crusher or Rockster R900 impact crusher.

Most jaw crushers will crush soft rock quickly and easily. The ARK 704 jaw crusher would be a perfect machine for the job. Find a full list of the best stone and rock crushers here. Lets not forget about stone and rock screeners too - they are really important for making your DOT approved crushed stone product!

Machinery Partner’s experts are here to help

With so many heavy equipment options out there, deciding which machine is best for your job can be difficult. Our experts can help you make that choice. They will talk you through the stone you want to crush vs. the heavy equipment suitable to get the job done. We are always here to help you figure out which machine is right for you, your budget, and your business. Contact one of Machinery Partner’s crushing experts today for more information. Check out our range of stone crushing machines here, including impact crushers for sale!

Machinery Partner specializes in crushers, screeners, excavators, & more. We are also here to help with financing and maintenance of all our machines to keep you up and running!

FAQs: Crushing Stone on Site

What is the easiest type of stone to crush?

Materials like limestone, shale, and sandstone are easier to crush. These are ideal for smaller crushers or entry-level setups and often don’t require as much power or wear part replacement.

What kind of crusher should I use for hard rock?

For tough materials like granite or basalt, start with a jaw crusher for primary crushing. If you need a cleaner or more uniform product, follow with an impact crusher for shaping.

Can I crush stone that has metal in it?

Yes. Many jaw crushers can handle reinforced concrete or mixed demolition material. A magnet can be added to remove metal like rebar or wire from the crushed output.

Do I need a screener after the crusher?

If you want sorted material by size, a screener is essential. It lets you separate fines from larger rock and create multiple products from a single load.

How much space do I need to crush stone on site?

Compact crusher and screener setups can run in tight spaces like driveways, small yards, or urban sites. You’ll need room for the machine, material piles, and safe access, but not much more.

Can I make money crushing stone?

Yes. Crushed stone sells well as base material, drainage rock, or clean fill. On-site crushing also cuts down on dumping fees, trucking, and buying aggregate, which improves margins quickly.

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