Waste rock refers to the rock debris produced during mining operations that does not contain economically valuable minerals. Sources of waste rock include rocks such as granite, basalt and limestone.
As global demand for sand and aggregates increases, waste rock processing offers a new solution to both sand shortages and mining waste accumulation worldwide.
Why use waste rock for sand processing?
Around 50 billion tons of sand and gravel are consumed globally each year, while mining operations generate approximately 30 to 60 billion tons of waste rock and tailings, creating significant opportunities for waste rock sand making.
Studies show that waste rock sand production can reduce carbon emissions and cut total production costs by approximately 20%.
Benefits of mining waste rock sand making:
- Raw materials are available on-site (no procurement cost)
- Reduces processing, transportation, and disposal costs
- Machine-made sand is stronger, cleaner, and often cheaper than natural sand
- Improves the overall resource utilization of mining sites
- Complies with environmental and green mining standards
With proper waste rock management and sand processing, waste rock can be transformed into high-value construction materials, and used in concrete, roads, bridges, asphalt and other projects.
How to turn mining waste rock into high-quality sand?
The typical waste rock sand making process includes the following steps:
- 1Primary and secondary crushing: Large waste rock (up to 1200 mm) is fed into a jaw crusher for initial crushing to 100–300 mm, then further reduced to 10–40 mm by a cone crusher.
- 2Sand making: The fine material is fed into a sand crusher(sand processing machine) to produce high-quality, cubical machine-made sand with 0–5 mm particle size.
- 3Screening: The multi-layer vibrating screen separates final sand from oversized material and impurities efficiently.
- 4Sand washing: The sand washer removes dust, clay, and impurities, ensuring clean and well-graded sand for construction use.
FTM Machinery provides high-capacity sand processing systems (10–1500 TPH) to help customers efficiently turn mining waste rock into high-quality manufactured sand. Talk to us
Essential equipment for waste rock sand making
A complete set of waste rock management and sand processing equipment is key to efficient resource reuse. With a systematic production flow, mining operations can turn waste rock into high-value construction sand, boosting output and environmental performance.
The process typically starts with crushing—here are the main machines used in waste rock sand making:
Waste rock crushers
Waste rock crushing is the first step in the sand making process, which is usually divided into primary crushing and secondary crushing.
Primary crushing typically uses a jaw rock crusher, ideal for breaking hard rocks like granite and basalt into smaller pieces.
Secondary crushing is handled by a cone rock crusher, further reducing the material into finer particles, preparing it for the next stage of sand production.
| Equipment | Jaw crusher | Cone crusher |
| Application | Primary crushing of large waste rock | Secondary crushing for finer output |
| Feeding size | Up to 1200 mm | Up to 480 mm |
| Output size | 10–350 mm | 6–50 mm |
| Capacity | 1–1590 TPH | 25–2181 TPH |
| Features | High crushing ratio, durable frame | Excellent particle shape, high efficiency |
Waste rock sand making machine
FTM Machinery's sand crusher uses intelligent technology to ensure uniform sand particle shape and optimal gradation.
With a strong, durable design and advanced wear-resistant materials, it stays reliable and lasts long even under continuous heavy-duty work.
Capacity: 80–650 TPH
Feeding size: ＜50 mm
Output size: 0–5 mm (adjustable)
Applications: Waste rock sand production, construction aggregates, road base materials.
Advantages: High sand production rate, up to 50% energy savings compared to traditional crushers, superior cubical shape with low flake content.
Waste rock sand washing machines
Sand washing equipment is used to remove dust, clay, and impurities from crushed sand, delivering clean and consistent quality. FTM Machinery offers both spiral sand washers and wheel sand washers to meet different project requirements.
| Features | Spiral sand washer | Wheel sand washer |
| Washing strength | Strong | Moderate |
| Water consumption | Higher | Lower |
| Sand loss rate | Moderate | Low |
| Suitable materials | Coarse and fine materials | Fine and medium sand |
FAQ: About mining waste and sand making
1. What is the difference between tailings and waste rock?
- Tailings and waste rock are two types of mining waste.
- Tailings are the fine materials left after useful minerals are extracted from ore. They are often in powder or mud form and may contain small amounts of metals and harmful substances, making them unsuitable for direct use.
- Waste rock, on the other hand, is unwanted rock or low-grade ore removed during mining to expose the ore body. It is usually large, hard, and strong in structure, making it ideal for waste rock sand making and crushed stone production.
2. Can manufactured sand replace natural sand in construction?
- Yes, manufactured sand (crushed sand) can replace natural sand for construction use. It offers stable quality, higher strength, and fewer impurities. Builders use it in concrete, road construction, and other projects. It meets strict standards for building materials.
3. Is waste rock sand making right for my mining site?
- Waste rock sand making is a good choice if:
- 1. There is strong local demand for sand and gravel (e.g., municipal projects, concrete mixing plants, highway construction).
- 2. Your mine has a large amount of good-quality, hard waste rock (like granite, limestone, or basalt).
- 3. Your company has or can invest in rock crushers, sand crushers, and sand processing equipment.
- 4. There is policy support for resource recycling, or you want to reduce waste stockpiles and improve your environmental image.
