850 TPH Modular Wash Plant | Amrize Case Study

Case Study

Modular Fusion® Wash Plant Delivers 5 Washed Products in Calgary

Location Calgary, AB

Industry Aggregates: Ready-Mix Concrete & Asphalt

The Challenge

As demand for washed aggregate products increased in the Calgary market, Amrize needed more production capacity to keep up with demand. Its existing wash plant had reached capacity limits, creating the need for a higher-output solution.

The site itself presented additional challenges. Highly abrasive feed material accelerated wear on transfer points, piping, and crushing equipment, while the temporary nature of the operation required a plant that could be relocated in the future without the complexity of a traditional stationary system.

Amrize needed a high capacity wash plant capable of producing multiple in-spec products while also delivering fast installation, modularity, and strong local support.

Equipment

Aggredry® Washer
Classifying Tank
Fusion® Platorm
Portable Jump Conveyors
Spirit® Sand Plant
Guardian® Screen

The Solution

To meet those goals, Amrize partnered with Superior's local dealer Machinery Supply to design and install a new high-capacity Fusion® Wash Plant tailored specifically to the site’s feed material and production requirements.

The pre-engineered system includes:

Twin 8x20 Guardian® Screens
12x48 Classification Tank
Twin 60-inch Aggredry® Washers
Single 48-inch Aggredry Washer
Spirit® Ultra-Fines Recovery Plant
35 integrated conveyors

Material is fed into the plant through a twin feeder system before being split between the two wash screens. The system separates multiple coarse aggregate products while simultaneously classifying product into concrete sand, mortar sand, and recovered fines.

Because the operation is expected to relocate in the future, the Fusion platform’s modular design played a major role in the purchasing decision. The system arrived clearly labeled for assembly, allowing Amrize crews to complete much of the installation on their own.

Throughout commissioning and startup, Machinery Supply worked closely with plant personnel to streamline setup and quickly dial in production.

The Results

The upgraded wash plant immediately expanded Amrize’s production capabilities, now at 850 tons per hour, while producing five specialty products for concrete and asphalt needs.

During one recent night shift, the plant produced nearly 10,000 metric tons of material in a single shift.

In addition to increasing throughput, the Spirit® Ultra-Fines Recovery Plant helps minimize the amount of material sent to settling ponds, improving overall site efficiency.

By combining high-capacity washing with modularity, the new Fusion wash plant positions Amrize to meet growing market demand while staying flexible for future the future.

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