Choosing the right demolition crusher sizing guide isn’t just about finding the biggest machine available. It’s about matching equipment capacity to your actual project needs, crew size, and workflow demands through proper crusher capacity planning. Get it wrong, and you’ll either waste money on unused capacity or create bottlenecks that slow down your entire operation.
Let’s break down how to size a demolition crusher properly so your team stays productive and your projects stay profitable.
Understanding Project Volume Requirements
Project volume crusher selection is the starting point for crusher sizing, but it’s not as simple as matching tons per hour to your total material. You need to think about realistic daily processing targets based on your crew’s capabilities and job site conditions.
For medium demolition projects, typically involving 500 to 2,000 tons of concrete, brick, and asphalt, you’re looking at crushers that can process 30 to 90 tons per hour. That range accounts for:
- Material variations throughout the day
- Loading and repositioning time
- Breaks and shift changes
- Weather delays and unexpected obstacles
A crusher rated at 90 TPH doesn’t mean you’ll process 720 tons in an eight-hour day. Real-world productivity typically runs at 60-70% of rated capacity once you factor in all the variables. Therefore, plan your crusher selection around actual achievable output, not theoretical maximums.
Matching Crusher Capacity to Your Crew Size
Your crew size directly impacts how much material you can realistically feed and manage. A 5-10 person demolition team needs equipment that matches their material handling capacity without creating idle time or overwhelming operators through effective crew workflow optimization crushers.
For teams in this range, compact crushers like the K-JC 604 or K-JC 704 PLUS offer the ideal balance. These machines deliver 50-90 tons per hour, which aligns perfectly with what a mid-sized crew can demo, load, and process efficiently. Key considerations include:
- Loading capacity: Can your crew keep the crusher fed consistently?
- Material preparation: Does someone need to pre-sort or break down oversized pieces?
- Stockpile management: Who handles the crushed material output?
- Equipment operation: Do you have a dedicated operator or is someone multitasking?
Oversizing creates expensive downtime. A massive crusher sitting idle while your crew struggles to keep up wastes fuel, increases wear, and ties up capital. Right-sizing means your equipment works as hard as your team does.
Key Workflow Factors That Impact Crusher Selection
Beyond volume and crew size, several workflow factors determine which crusher fits your operation best. These elements often make the difference between smooth daily operations and constant frustration.
Material Type and Variability
Demolition sites rarely produce uniform material. You’ll process concrete one hour, asphalt the next, and brick-filled rubble after that. Compact crushers with adjustable settings handle this variability better than specialized machines. The K-JC 704 PLUS, for instance, offers hydraulically adjustable output from 3/4″ to 3-1/4″, letting you adapt on the fly without stopping production.
Site Access and Mobility
Tight urban sites demand compact, mobile crushers that fit through standard gates and navigate confined spaces. Mobile demolition equipment sizing is critical here—track-mounted units like those from Komplet America move easily between areas without requiring heavy transport equipment. This mobility cuts setup time and lets you process material exactly where it’s generated.
Processing Speed and Throughput
Match your crusher’s speed to your excavator’s output for maximum on-site crusher productivity. If your crew can load 40 tons per hour but your crusher only handles 30, you’re creating a bottleneck. Conversely, a 90 TPH crusher fed by a crew producing 50 tons per hour means wasted capacity and higher operating costs.
Multi-Shift Operations
Running multiple shifts changes everything. Extended hours mean you need reliable, fuel-efficient equipment that won’t break down mid-shift. Machines with robust engines and simplified maintenance keep production moving when you’re operating 12-16 hours daily. Compact crushers built for continuous duty, like the K-JC 805, handle extended operations without excessive wear.
Common Sizing Mistakes Contractors Make
Even experienced contractors fall into these traps when selecting demolition crushers:
Mistake 1: Buying Based on Peak Demand
Sizing for your busiest day of the year leaves you with oversized, underutilized equipment 90% of the time. Instead, size for typical projects and rent additional capacity for exceptional situations.
Mistake 2: Ignoring Transportation Logistics
That powerful crusher means nothing if you can’t get it to your job sites. Compact models under 30,000 pounds transport easily on standard trailers without special permits or escort vehicles, saving time and money on every move.
Mistake 3: Overlooking Output Quality
Not all crushers produce the same output quality. If your recycled aggregate needs to meet specific gradation requirements, you need precise jaw adjustment and consistent crushing action. Cheaper, oversized crushers often produce inconsistent material that requires additional screening.
Mistake 4: Forgetting About Operator Skill Level
Complex machines require experienced operators. Compact crushers with intuitive controls and remote operation let less experienced crew members run equipment safely and efficiently, reducing labor costs and training time.
Sizing Examples: Komplet Crushers for Medium Demolition Projects
Let’s look at real-world sizing scenarios for medium demolition projects with 5-10 person crews:
Scenario 1: Urban Multi-Story Demolition
A six-person crew tackling a three-story commercial building generates approximately 50-60 tons of concrete and brick daily. The K-JC 604 handles this volume perfectly, processing material as fast as the crew can load it while fitting through narrow urban access points.
Scenario 2: Parking Lot Removal and Recycling
An eight-person crew removing 1,200 tons of asphalt and concrete over three weeks needs consistent daily output. The K-JC 704 PLUS delivers up to 90 TPH capacity, giving the crew room to push production on good weather days while maintaining efficiency during slower periods.
Scenario 3: Mixed Material Processing
A ten-person crew handling varied demolition waste needs flexibility. The K-IC 70 impact crusher processes softer materials like asphalt and brick efficiently while adjusting easily for concrete, keeping the entire crew productive regardless of material type.
Conclusion
Sizing a demolition crusher correctly means balancing project volume, crew capacity, and workflow demands. For medium demolition projects with 5-10 person teams, compact crushers delivering 30-90 tons per hour provide the sweet spot between productivity and practicality. Moreover, factors like material type, site access, and operating hours all influence which machine fits your needs best.
Komplet America offers a complete range of compact demolition crushers engineered for real-world contractor needs. From the nimble K-JC 503 to the powerful K-JC 805, there’s a properly sized solution for every medium demolition project. Request a quote from Komplet America today to find the crusher that matches your crew’s workflow and keeps your projects moving efficiently.
