850 TPH Portable Wash Plant | Amrize Case Study

Case Study

Portable Fusion® Wash Plant Delivers 850 TPH Production 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 ready-mix concrete and asphalt 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-capcaity wash plant capable of producing multiple in-spec products while also delivering portability, fast installation, and strong local dealer 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 local dealer Machinery Supply and Superior Industries to design and install a new high-capacity Fusion® Wash Plant tailored specifically to the site’s feed material and production requirements.

The turnkey system includes:

Twin 8x20 Guardian® Screens
12x48 Classification Tank
Twin 60-inch Aggredry® Dewatering 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 Fusion wash screens. The system separates multiple coarse aggregate products while simultaneously classifying sand into concrete sand, mortar sand, and recovered fines products.

Because the operation is expected to relocate in the future, the Fusion platform’s transport-friendly design played a major role in the purchasing decision. The modular system arrived clearly labeled for assembly, allowing Amrize crews to complete much of the installation in the field with minimal outside assistance.

Throughout commissioning and startup, Machinery Supply and Superior teams 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. Today, the plant operates between 800 and 850 tons per hour while producing five specialty aggregate products for concrete and asphalt applications throughout the region.

The operation has also seen major improvements in production efficiency and stockpile management. 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, reducing cleanup requirements and improving overall site efficiency.

By combining high-capacity washing performance with modular portability and strong local dealer support, the new Fusion wash plant positions Amrize to meet growing market demand while maintaining the flexibility needed for future relocation plans.

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