A yard of #57 stone weighs 2,600 lbs. A Toyota Tacoma payload: 1,685 lbs. You can fit 1.2 cubic yards in the bed. You can safely carry 0.6 cubic yards by weight. One full yard does not fit.

This gap between volume capacity and weight capacity is the mistake that cracks frames, blows tires, and gets trucks pulled over at DOT scales. Your truck bed holds 2 yards of space. Your axles handle less than 1 yard of stone.

This guide covers weight per cubic yard for 22 common materials, rated payload for 10 vehicle classes, and the math that connects them. Print the tables. Run the numbers before you load.

What Does a Yard of Material Weigh?

How much does a yard of gravel weigh? That depends on which material you mean. A yard of dry sand weighs 2,700 lbs. A yard of mulch weighs 600 lbs. The range across common construction and landscape materials spans 400 lbs to 3,400 lbs per cubic yard.

Aggregates

Organic Materials

Demolition Debris

Processed Fill

The takeaway: aggregates run 2,500 to 3,400 lbs per yard. Demo debris runs 2,000 to 3,200 lbs. Organic materials run 400 to 1,400 lbs. That 3x to 8x weight difference is why the same truck bed handles very different loads.

Moisture changes everything. Topsoil jumps 50% heavier after rain. Sand gains 15%. Crusher run swings from 2,500 lbs dry to 2,900 lbs wet. Wood chips double in weight when freshly chipped versus kiln-dried. If you loaded a material dry last week and plan to load it after a rainstorm, recalculate. The truck does not care what the material weighed on the spec sheet. It cares what the material weighs right now.

For a full breakdown of crushed stone sizes and grades, including weight per cubic yard by grade number, see our reference chart.

Volume Capacity vs. Weight Capacity: The Trap That Breaks Trucks

Every truck has two capacities. Volume: how many cubic yards fit in the bed. Payload: how many pounds the chassis, axles, tires, and brakes can handle. These two numbers almost never align.

Here is a visual way to think about it. A standard pickup bed is a box that holds about 2 cubic yards. Picture that box full of stone. Now picture that same box full of mulch. Both loads fill the same space. One weighs 5,200 lbs. The other weighs 1,200 lbs. Same volume, wildly different weight. The truck does not care how full the bed looks. It cares how much the load weighs.

Heavy Material Example: F-150 + #57 Stone

An F-150 with a 6.5-foot bed holds about 2 cubic yards level (62 cubic feet of interior volume, minus wheel well intrusion). #57 stone weighs 2,600 lbs per yard.

• 2.0 cubic yards x 2,600 lbs = 5,200 lbs
• F-150 payload (XLT, 2025): 1,800 lbs
• Over by 3,400 lbs at a full bed

Fill that bed to the rails with stone and you are carrying nearly triple the rated payload. The suspension compresses. The rear bumper drops toward the tires. Braking distance doubles and steering gets loose.

The safe amount: 0.7 cubic yards. About a third of the bed.

Light Material Example: F-150 + Mulch

Same truck, different material. Mulch weighs 600 lbs per yard.

• 2.0 cubic yards x 600 lbs = 1,200 lbs
• F-150 payload: 1,800 lbs
• Under payload by 600 lbs

The bed is full but the truck barely notices. Volume limits you before weight does.

The rule: Light materials fill your bed. Heavy materials break your axles. Always check BOTH numbers.

The Quick Math

For any material and any vehicle, the safe load is whichever number is lower:

Safe cubic yards = LOWER of (bed volume) or (payload lbs / material weight per yd)

Example: F-250 with 2.0 yd bed and 4,000 lb payload hauling #57 stone at 2,600 lbs/yd.

• Volume limit: 2.0 yd
• Weight limit: 4,000 / 2,600 = 1.5 yd
• Safe load: 1.5 yd (weight is the bottleneck)

Same truck hauling mulch at 600 lbs/yd:

• Volume limit: 2.0 yd
• Weight limit: 4,000 / 600 = 6.7 yd
• Safe load: 2.0 yd (volume is the bottleneck)

Run this formula for every load. It takes 10 seconds and prevents a $5,000 repair bill.

How Much Can Your Truck Actually Carry?

Ten vehicle classes from a half-ton pickup to a tri-axle dump. Bed volume, rated payload, and max safe cubic yards of three reference materials: #57 stone (heavy), mulch (light), and dry topsoil (medium).

Every pickup is weight-limited on stone. You hit payload before you fill the bed. Even the F-350 DRW (2.5 yd bed, 2.1 yd safe stone) leaves nearly half a yard of empty bed at max weight. Dump trailers are the first vehicles where volume and weight roughly balance on heavy aggregate.

Every pickup is volume-limited on mulch. Payload is not the problem. Bed size is.

Note: Subtract 300 to 500 lbs from rated payload for driver weight, toolbox, hitch, and gear. A 1,800-lb F-150 payload becomes 1,300 to 1,500 lbs in the real world. That drops your safe stone load from 0.7 to 0.5 cubic yards.

How to find your truck’s payload. Open the driver door and look for the yellow and white tire and loading information sticker. It lists the maximum combined weight of occupants and cargo. That is your payload. Not the towing sticker. Not the GVWR plate on the door jamb (GVWR minus curb weight equals payload, but the sticker does the math for you). Every truck off the assembly line gets a unique payload number based on its specific options, cab size, and engine.

Payload varies by configuration. The F-250 XLT ranges from 3,546 to 4,240 lbs depending on engine and drivetrain. The 4,000 lbs shown above represents the gas V8 crew cab. Your specific truck may differ by 500 lbs or more. Check the door sticker.

Dump truck capacities match standard industry ranges: single-axle 6 to 8 tons, tandem 15 to 18 tons, tri-axle 20 to 24 tons. See the delivery logistics section in our crushed stone calculator for delivery fee math.

How Many Yards Can You Haul?

The tables above show three materials. Below are all 22 materials in four hauling groups with the safe maximum cubic yards per vehicle. Every value accounts for both volume and payload limits. Rounded to nearest 0.1 yd.

Aggregates (Highest Overload Risk)

Every pickup in this table is weight-limited. You hit payload before you fill the bed on any aggregate material.

Organic Materials (Volume-Limited)

Mulch, chips, and compost are volume-limited on every vehicle. The bed fills before payload matters. Three exceptions: stumps, wet topsoil, and compost in a Tacoma. Stumps with root balls weigh as much as dry topsoil (2,000 lbs/yd) and weight-limit pickups the same way stone does. Wet topsoil after rain behaves like aggregate. Check your material and the forecast before you load.

Demolition Debris

Brick is the heaviest common demo material at 3,000 lbs per yard. An F-150 carries 0.6 cubic yards of brick, barely enough to cover the bed floor. Concrete rubble is lighter than most people expect because the broken pieces leave air voids (solid concrete weighs 4,050 lbs/yd; rubble runs 2,000 to 2,500). Every demo material except mixed C&D weight-limits pickups.

Processed Fill

How Many Trips Does Your Job Take?

Three common scenarios with trip counts and costs.

Scenario A: 10 Cubic Yards of #57 Stone for a Driveway

F-350 DRW: 10 / 2.1 = 5 trips. At 30 minutes per round trip to the quarry, that is 2.5 hours of driving plus loading time.

Medium dump trailer: 10 / 3.8 = 3 trips. You need a 3/4-ton or 1-ton truck to tow a loaded medium dump trailer carrying 9,880 lbs of stone.

Tandem dump truck delivery: 10 yards at 1.30 tons per yard = 13 tons. One tandem load at $150 to $250 delivery fee. Done in one trip.

The delivery math usually wins. Five round trips in a pickup at 15 miles each way = 150 miles. At $0.70/mile (IRS rate), that is $105 in mileage alone. Add 4 hours of labor at $35/hr and you spent $245 in time and fuel. One $200 dump truck delivery saves money and frees you to work the job. For full tonnage calculations, see our crushed stone calculator.

Scenario B: 15 Cubic Yards of Mulch for a Landscape Project

Medium dump trailer: 15 / 5.0 = 3 trips. Mulch is volume-limited, so 5 cubic yards fills the trailer at only 3,000 lbs. Light towing. Any half-ton truck handles this load. The bottleneck is trailer size, not truck capability.

F-150: 15 / 2.0 = 8 trips. Possible but painful. At 20 minutes per round trip, that is nearly 3 hours of driving. Rent a dump trailer for $150/day and cut it to 3 trips.

Bulk delivery: Many mulch suppliers deliver 10 to 15 cubic yards in a single dump truck load for $75 to $150. Cheaper than a trailer rental if you do not already own one.

Scenario C: 50 Tons of Concrete Debris from a Demo Job

Tandem dump truck: 50 tons at 15 tons per load (conservative) = 4 loads. At $150 to $250 per haul, trucking runs $600 to $1,000.

Add tipping fees at the receiving facility: $35 to $55 per ton in most Southeast markets. That is 50 tons x $45 average = $2,250 in disposal alone. Total haul-and-dump cost: $2,850 to $3,250.

That $2,850 to $3,250 disappears if you crush the concrete on-site and reuse it as base aggregate. More on that in Section 8 below.

Our tonnage estimation guide has formulas for sizing demo jobs before the first hammer swing. Ordering stone? The crushed stone calculator covers waste factors, and our crusher run guide covers settlement: order 15 to 25% more than the math says.

When to Self-Haul vs. Hire Delivery

Self-hauling makes sense in three situations. First: you already own a dump trailer and the supply yard is under 10 miles away. Second: you only need 1 to 2 cubic yards of light material like mulch or topsoil that fits in your pickup. Third: you need material at odd hours when delivery is not available.

Hire delivery for everything else. On any job over 5 cubic yards of aggregate, the delivery fee is cheaper than your fuel, time, and vehicle wear. On any job over 10 yards, it is not even close. A tandem dump truck delivers 12 yards of stone in one trip for $150 to $250. That same 12 yards would take 6 trips in an F-350 DRW at 2.1 yards per trip.

The break-even point for most contractors: about 3 cubic yards of heavy material. Below that, self-haul. Above that, call the truck.

What Happens When You Overload

Overloading is not a “maybe it will be fine” situation. Every supply yard in the country sees trucks leave overloaded every day. The guy at the loader asks how much you want. You say “fill it up.” He fills it up. Nobody runs the payload math. Here are the four categories of consequences.

Safety

• Blown tires. Tire load ratings are absolute. An OEM truck tire on a Tacoma is rated for roughly 2,500 to 2,700 lbs per tire depending on size and load index. Exceed the rating and the tire overheats and fails at highway speed.
• Brake fade. Braking distance increases in direct proportion to load. Double the payload, double the stopping distance. Downhill with stone and faded brakes is how wrecks happen.
• Suspension failure. Leaf springs crack. Shocks bottom out. The rear axle contacts the bump stops and stays there. Steering goes vague because the front tires are unloaded.

Legal

• DOT fines. Overweight citations range from $100 to $500+ per 1,000 lbs over in most states.
• CDL threshold. A combined GVWR over 26,001 lbs means you need a CDL. A 3/4-ton truck (10,000 lb GVWR) plus a loaded medium dump trailer (14,000 lb GVWR) = 24,000 lbs. Add 2,001 lbs of overload and you crossed a legal line.
• Insurance void. Exceeding rated GVWR can void your vehicle insurance. Wreck while overloaded and your insurer denies the claim. Liability coverage may also be affected. If you injure someone while operating an overloaded vehicle, your personal assets are exposed.

Vehicle Damage

Warped frames, cracked leaf springs, premature drivetrain wear, bent axle housings, and transmission overheating. A leaf spring replacement on an F-250 runs $800 to $1,500 in parts and labor. A warped frame is a total loss on most trucks. One overloaded trip often costs more in repairs than two proper trips would have cost in time and fuel.

The visual test: If the rear bumper sits level with the tires, you are over. Step out and look before you leave the yard.

For federal weight limits on public roads, see the FHWA bridge formula and weight limits.

The Real Answer: Process Material On-Site

Every trip calculation in this guide assumes you are hauling material from point A to point B. The alternative: bring the processing equipment to the material and skip hauling entirely.

Concrete debris: A portable jaw crusher turns 50 tons of broken concrete into reusable base aggregate on the same site. Zero haul trips. Zero tipping fees. Zero payload math. The crusher does the work where the material sits. On-site crushing costs $5 to $12 per ton. Hauling to a landfill costs $35 to $55 per ton in tipping fees plus $150 to $250 per truckload in trucking. On a 50-ton job, that is $250 to $600 for crushing versus $2,850 to $3,250 for hauling. See our guide to on-site concrete crushing for the full process and cost breakdown.

Raw topsoil and fill: A trommel screen separates clean topsoil from rocks, roots, and debris on-site. No trucking raw material to a processing yard and back. A CZ Screen M412 MIDI processes 30 to 50 cubic yards per hour. Feed in rough fill, get back clean topsoil off one belt and rock off the other. Screen it on your lot and stockpile the finished product. Screened topsoil sells for $25 to $45 per yard at landscape supply yards. Unscreened fill is worth $5 to $10. The screen turns a low-value pile into a sellable product.

Mixed aggregates: A vibratory screener sorts stockpiled material into graded products. Clean stone off one belt, fines off another, oversize off the third. Three products from one feed. No trips to three different suppliers. No loading, hauling, or unloading at each stop.

GrinderCrusherScreen has connected contractors with portable crushing and screening equipment since 1973. We do not own or operate machinery. We match you with the right equipment for your job. Call 770-433-2670 or visit the concrete crusher rental, trommel screen rental, or screener rental pages for pricing.

Frequently Asked Questions

How much does a yard of gravel weigh?

A cubic yard of natural washed gravel weighs about 2,800 lbs (1.40 tons). Crushed stone (#57) weighs about 2,600 lbs per yard (1.30 tons). Crusher run weighs 2,500 to 2,900 lbs per yard depending on moisture content.

The term “gravel” covers different products at different supply yards. Natural gravel (rounded river stone) is slightly heavier than crushed stone because the smooth particles pack tighter with fewer air voids. Always confirm the exact weight with your supplier, since source rock and gradation affect density.

Can I haul a yard of gravel in a pickup truck?

It depends on the material and the truck. A Ford F-150 has a payload of about 1,800 lbs and a 6.5-foot bed that holds roughly 2 cubic yards. One cubic yard of #57 stone weighs 2,600 lbs. That is 800 lbs over the rated payload. You cannot safely carry a full yard of stone in an F-150.

You can carry 0.7 cubic yards of stone, or a full bed of mulch (1,200 lbs), within the payload rating. An F-250 with a 4,000-lb payload handles about 1.5 cubic yards of stone. An F-350 DRW with a 5,500-lb payload handles 2.1 cubic yards. Check the payload sticker on your driver door jamb and do the weight math before you load.

How much does a yard of mulch weigh?

Natural bark mulch weighs 400 to 600 lbs per cubic yard. Colored mulch runs slightly heavier at 500 to 700 lbs because the dye and added moisture increase density. Fresh wood chips weigh 600 to 1,000 lbs per yard depending on species and moisture content.

Mulch is always volume-limited in pickup trucks. The bed fills long before you approach the payload limit. A standard F-150 bed holds about 2 cubic yards of mulch at roughly 1,200 lbs total, well under the 1,800-lb payload. If you need more than 2 cubic yards of mulch, a dump trailer or bulk delivery is the practical move.

What is the difference between payload and towing capacity?

Payload is the total weight you put IN and ON the truck. That includes bed cargo, passengers, toolboxes, and hitch weight from a trailer. Towing capacity is the total weight the truck can pull BEHIND it. They are separate ratings and both have limits.

Loading stone in the bed uses payload. Pulling a loaded dump trailer uses towing capacity AND payload, since tongue weight counts against your payload number. You must stay under both ratings at the same time.

A common mistake: a contractor with a 10,000-lb towing capacity thinks he can tow a 10,000-lb loaded trailer. But the 800-lb tongue weight of that trailer counts against his 1,800-lb payload. Add a driver and toolbox and he is already close to payload limit before the bed is loaded. The payload rating is on the yellow sticker on the driver door jamb. Towing capacity is in the owner’s manual.

How many yards of dirt can a dump truck carry?

A single-axle dump truck carries about 5 cubic yards (5 to 7 tons of dirt). A tandem carries about 12 cubic yards (12 to 16 tons). A tri-axle carries about 16 cubic yards (16 to 22 tons).

Dirt weight varies by type: clean fill dirt runs about 2,200 to 2,600 lbs per yard, while wet clay runs 2,800 to 3,200 lbs per yard. Always ask if the dirt has been sitting in rain. A stockpile that started at 2,400 lbs per yard can hit 3,000 lbs after a week of storms.

Dump trucks are sized so that volume and payload roughly balance for most materials. Unlike pickups, dump trucks rarely face the volume vs. weight trap because both capacities are built for heavy loads.

Tipping fees are the single biggest line item most contractors forget to bid. A 200-ton concrete demo job in Florida costs $10,500 in disposal fees alone. That number hits before you load the first truck.

This guide breaks down what tipping fees are, what they cost state by state, and three ways to cut them to zero.

What Is a Tipping Fee?

A tipping fee is the per-ton charge a landfill, transfer station, or recycling facility charges to accept your waste. The name comes from the action: you back up to the working face, “tip” your load, and pay at the scale house on the way out.

Most construction and demolition (C&D) facilities charge per ton. The truck rolls across an inbound scale, dumps, then rolls across the outbound scale. The weight difference is your billable tonnage. Some smaller operations charge per cubic yard or flat per-load fees instead, but ton-based pricing is the industry standard at permitted C&D landfills.

The fee varies by material type too. Clean concrete typically gets a lower gate rate than mixed C&D loads. Loads with contaminants (lead paint, asbestos-containing drywall) cost more because they require special handling cells.

Three things drive tipping fee rates:

1. Operating costs. Dozers, compactors, labor, and diesel to spread and compact waste daily. 2. Environmental compliance. Liner systems, leachate collection, groundwater monitoring wells, stormwater ponds, and air quality permits all add cost per ton. 3. Closure and post-closure funds. Federal law requires every landfill to set aside money for final capping, grading, revegetation, and 30 years of post-closure groundwater monitoring.

These costs get passed directly to you at the scale house. And they rise every year. Tipping fees have increased faster than inflation in recent years. The national average rose 10% in a single year between 2023 and 2024, reaching $62.28 per ton for municipal solid waste. The EPA estimates over 600 million tons of C&D debris are generated in the US each year, and disposal costs climb as landfill capacity tightens.

How Much Are Tipping Fees? State-by-State Rates

Tipping fees vary by state, county, facility, and material type. C&D waste (concrete, asphalt, wood, drywall) usually costs less than municipal solid waste (MSW) because it takes up more space but poses fewer contamination risks.

Here are average C&D tipping fee rates for six Southeast states:

Key variables that shift your actual rate:

• Material type. Clean concrete often gets a lower rate than mixed C&D. Vegetative waste sometimes has a separate, cheaper fee. Contaminated material (painted wood, drywall with lead paint) costs significantly more.
• Volume commitments. Some facilities offer discounted rates for contractors who bring consistent volume.
• Distance from metro areas. Rural landfills with open capacity tend to charge less than urban transfer stations.

MSW tipping fees run 20-40% higher than C&D rates at most facilities. Vegetative waste (stumps, brush, logs) often gets a separate, lower rate at facilities that grind and mulch it.

One more thing to watch: surcharges. Many landfills add fuel surcharges, environmental fees, or gate fees on top of the published per-ton rate. Always ask for the “all-in” gate rate before you bid a job. A $45/ton posted rate can turn into $52/ton after surcharges.

The Real Cost of Tipping Fees on a Demo Job

Tipping fees are only part of the disposal bill. Every ton you haul off-site also costs you trucking, driver time, and lost production on the demo site. Here is a real example.

Job: 200-ton concrete slab demo in Central Florida.

That $12,550 is pure disposal cost. No demo labor. No excavator rental. No site prep. No profit margin. For a deeper look at concrete disposal economics specifically, see our concrete disposal cost breakdown.

On most demo jobs, haul-out and disposal eat 15-25% of the total project budget. On smaller slabs and foundations, the percentage climbs even higher because the fixed costs (mobilization, permits, traffic control) stay the same regardless of tonnage.

Now multiply that across a year of jobs. A mid-size demo contractor running 15-20 jobs per year can easily spend $150,000-$250,000 annually on tipping fees and trucking.

Every haul trip also burns production time. Your excavator sits idle while the truck runs to the landfill and back. A two-hour round trip is standard. On a 10-load job, that is 20 hours of gate-to-gate trucking. Your operator waits. Your timeline stretches. Your overhead keeps ticking.

There is also a hidden cost most contractors miss: fuel. A loaded tri-axle burns roughly 4-5 gallons per hour. Ten round trips at two hours each uses 80-100 gallons of diesel. At $4/gallon, that adds $320-$400 to the disposal bill that never shows up on the tipping receipt.

Three Ways to Reduce or Eliminate Tipping Fees

The math changes when you process material on-site instead of hauling it to a landfill. Here are three methods that work.

1. On-Site Crushing

A portable jaw crusher turns reinforced concrete into reusable aggregate right on the demo site. Your excavator feeds broken slab into the hopper. The crusher processes rebar-reinforced concrete and outputs 3/4-inch minus base material. That crushed product works as road base, pipe bedding, backfill, or parking lot sub-base.

The numbers on that 200-ton Florida job:

• Tipping fees eliminated: $10,500
• Trucking eliminated: $1,350
• Driver time eliminated: $700
• Value of crushed base material (200 tons x ~$12/ton): $2,400
• Total swing: $14,950

A compact crusher like the Evortle CT-535 handles jobs in the 50-150 ton range. For larger demo work (parking structures, bridge decks, commercial foundations), the CT-850 processes 65 to 130 tons per hour. For a step-by-step walkthrough of the crushing process, see how on-site concrete crushing works.

See available concrete crushers in the Southeast.

2. On-Site Screening

A trommel screen separates mixed material into clean, reusable fractions. Feed goes into the rotating drum. Clean soil drops through the screen openings. Oversize rock and aggregate discharge off the end. Debris and trash get sorted out separately.

The result: 60-70% of your material stays on-site as usable fill or topsoil. Only the contaminated fraction goes to the landfill. That cuts your tipping fees, trucking, and haul time by roughly the same percentage.

Screening works well on excavation spoils, land-clearing sites with mixed fill, utility trenching backfill, and any job where dirt and debris are mixed together. Instead of paying $45/ton to dump clean soil at a landfill, you screen it and reuse it on the same project.

See available trommel screens in the Southeast.

3. On-Site Burning

An air curtain burner processes vegetative waste on the job site: trees, stumps, brush, root balls, and land-clearing debris. A high-velocity curtain of air feeds the fire pit, holding combustion temperatures above 1,800 degrees F. That high heat reduces wood waste volume by roughly 95%.

Here is what that means in practice. A 500-cubic-yard brush pile from a 10-acre clearing job burns down to a few cubic yards of ash. That is 25 truckloads reduced to one. At $35/ton tipping and $135/load trucking, burning saves $4,000-$6,000 on a single clearing job.

Most Southeast states allow air curtain burners in counties where open pile burning is banned. The controlled combustion produces far less smoke and particulate than open burning, which makes permitting easier.

See available air burners in the Southeast.

When On-Site Processing Beats Hauling

Not every job justifies renting a crusher or a screen. Here is a quick sizing guide.

At a $45/ton tipping fee, the break-even point for a crusher rental is roughly 50 tons. Below that, the rental mobilization cost exceeds what you save on tipping and trucking.

Other factors that tip the math toward on-site processing:

• Long haul distances. If the nearest C&D facility is 30+ miles away, trucking costs climb fast. A 60-mile round trip at $4.50/mile loaded adds $270 per trip before you even pay the tipping fee.
• Reuse potential. If the project needs fill, base, or grading material, crushed concrete or screened soil eliminates a separate purchase. You avoid paying for disposal and avoid paying for new aggregate.
• Tight schedules. Hauling 200 tons takes 10 truck loads over two or more days. A crusher processes 200 tons in a single shift. That schedule compression matters on jobs with liquidated damages or tight turnover deadlines.
• Multiple material types. Jobs with both concrete and vegetative waste can pair a crusher with an air burner. The crusher handles the hard material. The burner handles the wood waste. Nothing goes to the landfill.

Stop Paying to Throw Away Reusable Material

Tipping fees drain project budgets on every demo and site-clearing job in the Southeast. Rates average $35-$52 per ton today and keep climbing as landfill capacity tightens. The contractors who keep more profit per job are the ones who process material on-site instead of hauling it to the dump.

GrinderCrusherScreen has connected contractors with portable crushers, trommel screens, and air burners since 1973. Call 770-433-2670 to get matched with a provider in your area, or browse equipment at grindercrusherscreen.com.

Concrete disposal runs between $15 and $55 per ton at the gate. That number depends on your state, the type of facility, and how clean the material is. But that gate fee is only part of the story. Once you add trucking, loading, and driver wait time, most contractors pay $25 to $80 per ton all-in.

There is another option. Crush it on-site, skip the landfill entirely, and turn demo waste into usable base material. Here is a full cost breakdown of both approaches so you can run the numbers on your next job.

Concrete Disposal Cost Breakdown

Every haul trip has four cost layers. Most bids only account for the first one.

Tipping fees: $15 to $55 per ton. C&D landfills in the Southeast charge $15 to $30 per ton for clean concrete. Mixed loads with rebar, dirt, or wood waste push that to $40 to $55 per ton. Recycling centers that accept clean concrete typically charge $10 to $20 per ton, but they reject loads with contaminants.

Trucking: $4 to $6 per loaded mile (round-trip). A 20-ton end dump running 25 miles round-trip to the nearest C&D landfill costs $100 to $150 per trip. That is $5 to $7.50 added per ton just for the truck. Double the mileage and you double the freight cost.

Loading: $150 to $300 per hour. You need an excavator or skid steer with an operator to load trucks. A 150-ton job takes 8 loads in a 20-ton truck. At 20 to 30 minutes per load cycle, that is 3 to 4 hours of loader time: $450 to $1,200 depending on the machine and operator rate.

Wait time at the landfill: 30 to 60 minutes per load. During peak hours, trucks sit in line. At $85 to $125 per hour for a driver and truck, each wait adds $42 to $125 per load. Over 8 loads, that is $336 to $1,000 in dead time.

All-in cost per ton: $25 to $80. The exact number depends on haul distance, landfill rates in your area, load cleanliness, and how busy the facility is. But the gate fee alone never tells the full story.

Cost Comparison Table: Hauling vs. On-Site Crushing

This table shows total project costs at four common job sizes. Hauling assumes a 25-mile round-trip, $35/ton tipping fee, and $5/ton trucking. Crushing assumes weekly equipment rental, fuel, and operator costs.

The break-even point sits right around 50 tons. Below that, hauling is usually cheaper or close to even. Above 50 tons, the savings from on-site crushing climb fast. At 500 tons, you are cutting your disposal cost by more than half.

These numbers do not include the value of the crushed material you keep on-site. More on that below.

What Jaw Crushers Actually Process

Before you rent a crusher, know what it handles and what it does not.

Concrete (plain and rebar-reinforced): YES. Jaw crushers process concrete slabs, footings, walls, and foundations. Rebar is not a problem. The CT-850 includes a standard cross magnet that pulls rebar during processing. The CT-535 offers an optional magnet for the same function. The steel goes to a scrap pile, and you get clean aggregate.

Rock, brick, block, and C&D rubble: YES. Natural stone, CMU block, brick, and mixed masonry all run through a jaw crusher. The machine does not care if it is poured or laid.

Asphalt: NO. Jaw crushers do not process asphalt. The material is too soft and sticky for a jaw chamber. Asphalt recycling requires an impact crusher, which uses a different crushing action. Do not try to run asphalt through a jaw crusher.

The output: 3/4-inch minus aggregate. Adjust the CSS (closed-side setting) and you get material sized for base course, backfill, pipe bedding, or spec aggregate. Most contractors use the crushed output as road base or structural fill right on the same job site. That means zero haul trips out and zero haul trips in for new base material.

Two Models, Two Job Sizes

GrinderCrusherScreen connects contractors with two Evortle jaw crusher models. Each one fits a different scale of work.

Evortle CT-535: 14,330 lbs. Compact enough to ride on a tag-along trailer behind a one-ton pickup. Designed for residential tear-outs, small commercial demo, and tight job sites where a full-size crusher will not fit. Ideal for jobs under 200 tons.

Evortle CT-850: 52,910 lbs. This is a production machine. It ships on a lowboy and processes material at rates that keep up with large commercial and municipal demo projects. Built for jobs over 200 tons where throughput matters.

Quick sizing rule: Under 200 tons, the CT-535 handles it. Over 200 tons, step up to the CT-850. If you are tearing out a residential driveway or a small parking lot, the CT-535 is the right fit. If you are demolishing a warehouse floor or a multi-story foundation, the CT-850 pays for itself in speed. Not sure how much concrete you have? Our tonnage estimation guide has formulas for slabs, footings, and walls. For a step-by-step process walkthrough, see how on-site crushing works.

The Math on a Real Job

Here is a side-by-side on a real-world scenario: a 150-ton parking lot tear-out in Atlanta, GA.

Option A: Haul It Out

• Loads: 150 tons / 18.75 tons per truck = 8 loads
• Tipping fees: $45/ton x 18.75 tons = $843.75 per load x 8 loads = $6,750
• Trucking: $135 per load x 8 loads = $1,080
• Loading time: ~4 hours at $200/hr = $800
• Total haul-out cost: $8,630

Option B: Crush On-Site

• Weekly crusher rental (CT-535): ~$3,200
• Fuel: ~$500 for the week
• Operator (if needed): ~$500
• Total crushing cost: $4,200

The Bottom Line

Net savings: $4,430. That is a 51% reduction in disposal cost.

But it gets better. The crushed concrete you produced is worth money. At $12/ton for 3/4-inch minus base material, that 150 tons of aggregate has a value of $1,800. Use it as backfill on the same site, and you also skip buying and hauling in new base material.

Total economic advantage: $6,230 when you count both the disposal savings and the recovered material value.

Contractors running demo work in the Southeast see these numbers on nearly every job over 100 tons. The further your job site sits from the nearest C&D landfill, the more the math favors on-site crushing.

Looking at a project in Tampa, Jacksonville, or anywhere else in the Southeast? The same math applies. Haul distances and tipping fees vary by county, but the break-even stays around 50 tons in most markets.

Get Matched with a Crusher for Your Next Demo Job

GrinderCrusherScreen has connected contractors with heavy equipment since 1973. Tell us about your job: tonnage, material type, location, and timeline. We will match you with a crusher and get you a quote.

Call 770-433-2670 or visit the concrete crusher rental page to request pricing.

Looking to buy instead of rent? Browse concrete crushers for sale on GrinderCrusherScreen.com.

On-site concrete crushing turns demo rubble into reusable base aggregate without leaving the jobsite. No trucks. No landfill. No tipping fees. Here is how the process works and what it costs.

Step 1: Site Assessment and Equipment Sizing

Every crushing job starts with two questions: how much material do you have, and what is in it?

Estimate your tonnage. A 4-inch concrete slab weighs roughly 50 lbs per square foot, or about 2.5 tons per 100 square feet. A 2,000-square-foot driveway is roughly 50 tons. A 10,000-square-foot commercial slab at 6-inch thickness is around 375 tons. These are working estimates. Thicker slabs, footings, and structural walls weigh more per square foot.

Identify the material. Plain concrete, rebar-reinforced concrete, and mixed loads with brick or block all crush fine in a jaw crusher. Rebar is not a problem. The integrated magnet pulls it out during processing. But know what you are feeding the machine before you pick one. Heavy rebar (number 8 bar and above) affects feed rate and jaw wear.

Pick the right machine. Two models cover most jobs:

• Under 200 tons, light to moderate rebar: Evortle CT-535. 14,330 lbs. Compact. 20×14-inch jaw opening. Rides on a standard tag-along trailer. Fits through residential gates and into tight job sites.
• Over 200 tons or heavy reinforced: Evortle CT-850. 52,910 lbs. Production machine. 32×20-inch jaw opening. Handles structural concrete, bridge decks, and warehouse foundations at volume.

Not sure about your tonnage? Our demolition tonnage estimation guide has formulas for slabs, footings, walls, and common demo scenarios.

Check site access. The CT-535 tows behind a one-ton pickup and fits anywhere a dually can go. The CT-850 ships on a lowboy and needs open access for a 53-foot trailer. Measure your gate width and check overhead clearance before you order.

Step 2: Equipment Delivery and Setup

Delivery depends on the model.

CT-535: Ships on a standard tag-along trailer. Your tow vehicle: a one-ton pickup or medium-duty truck. Many contractors tow the CT-535 with equipment they already own. No oversize permits. No pilot cars.

CT-850: Ships on a lowboy. Requires a flatbed or specialized heavy-haul trailer. The trucking company handles delivery and pickup. Plan for lowboy access at the site entrance.

Setup time: 30 to 60 minutes for either model. Position the crusher near the rubble pile with the discharge conveyor pointing toward your stockpile area. Level the machine. Connect power. Run a test cycle. That is it. No foundation work, no crane lifts, no complicated assembly.

You need a feeding machine on-site: an excavator with a thumb or a skid steer with a grapple bucket. The excavator picks up broken concrete and drops it into the crusher hopper. If you are running a demo job, you already have the excavator on-site. The crusher plugs into your existing workflow.

Step 3: Crushing Operations

This is where concrete turns into aggregate.

The excavator feeds broken concrete into the crusher hopper. Jaw plates close and crush the material to the set CSS (closed side setting). CSS controls the output size. Set the CT-535 to its minimum 0.8-inch CSS and you get road base aggregate. The CT-850 produces a 1-inch minus product at its tightest setting. Need a coarser output for large fill? Open the CSS up.

The magnet does the dirty work. An overband magnet sits above the discharge conveyor. The CT-850 includes the magnet as standard equipment; on the CT-535, it is an available option. As crushed material exits the jaw chamber, the magnet pulls rebar, tie wire, and steel reinforcement out of the stream automatically. Steel goes to a scrap pile. Clean aggregate conveys to your stockpile on the opposite side.

Throughput depends on the model and the material. The CT-535 runs at a pace that matches residential and small commercial work. One excavator keeps it fed without waiting. The CT-850 runs production pace on large commercial sites. It eats material as fast as a 30-ton excavator can feed it.

Crew size: two people. One operator runs the excavator and feeds the crusher. The crusher runs itself once material hits the hopper. A second person monitors the stockpile, manages the scrap steel, and handles site logistics. On smaller jobs, a single operator can handle both roles.

Step 4: Material Grading and Use

The crusher output is 3/4-inch minus aggregate: a mix of crushed concrete particles from dust up to 3/4-inch diameter. This material is structurally sound and usable on most projects without further processing.

Common uses for crushed concrete aggregate:

• Road base and sub-base
• Parking lot base course
• Pipe bedding
• Structural backfill
• Foundation backfill
• Temporary haul roads and construction access

Many DOT specifications accept crushed concrete as base material. Check your local DOT spec before crushing. If your project requires a specific gradation, adjust the CSS before you start processing. Run a test batch and check the output against your spec.

What to do with excess material. Crush what you need for the current job. If you produce more aggregate than you can use, stockpile it for future projects. Neighboring contractors on adjacent sites often take excess base material. Crushed concrete at about $12 per ton is cheaper than buying virgin aggregate, so the material has real value.

What On-Site Crushing Costs

Three cost components make up your all-in number.

Equipment rental. Weekly rates vary by model and market. The CT-535 costs less per week than the CT-850. Contact GrinderCrusherScreen at 770-433-2670 for current pricing in your area.

Fuel. Both models run on diesel. Consumption depends on material hardness, feed rate, and how many hours per day you run. Harder concrete and higher feed rates burn more fuel. Budget accordingly based on your tonnage estimate.

Operator. If you have a skilled excavator operator on your crew, they can feed the crusher. No specialized training needed beyond a brief orientation on the machine controls. If you do not have an operator, contracted crushing services include the operator and the machine as a package.

All-in cost per ton for on-site crushing: typically $5 to $12 per ton depending on volume, model, and whether you supply your own operator.

Compare that to hauling: $25 to $80 per ton all-in once you add tipping fees, trucking, loading time, and driver wait time at the landfill.

The break-even point sits around 50 tons. Below that, hauling is often cheaper. Above 50 tons, the savings climb with every load you skip.

On-Site Crushing vs. Contracted Crushing

Two ways to get concrete crushed on your job site.

Option A: Rent the crusher. You provide the excavator, operator, and fuel. The crusher shows up on a trailer. You run it yourself. This costs less per ton but requires your own equipment and a skilled operator. Best for contractors who run demo work regularly and already have an excavator on-site.

Option B: Hire a contracted crushing service. A crushing operator brings the machine, runs it, and leaves when the job is done. Turnkey. You do not need your own excavator or operator. This costs more per ton but requires zero equipment investment from you. Best for one-off demo jobs or contractors without heavy equipment.

Which one fits your job? It depends on your tonnage, your equipment inventory, and your timeline. GrinderCrusherScreen connects you with both options. Tell us your tonnage, material type, and location. We will match you with a crusher rental or a contracted crushing operator, whichever fits.

Get Connected with a Crusher

GrinderCrusherScreen has connected contractors with heavy equipment since 1973. Whether you need to rent a jaw crusher or hire a contracted crushing crew, we match you with the right provider for your job.

Call 770-433-2670 or visit the concrete crusher rental page to request pricing.

Running a demo job in Atlanta, Nashville, or Tampa? We cover the entire Southeast.

Looking to buy instead of rent? Browse concrete crushers for sale on GrinderCrusherScreen.com.

Every crusher quote starts with the same question: how many tons? Get the tonnage wrong and you rent the wrong machine, schedule the wrong number of days, and blow your disposal budget. Here is how to estimate concrete tonnage for common demo scenarios.

Concrete Weight Basics

Start with three numbers. Memorize them.

Standard concrete: 150 lbs per cubic foot. That works out to 4,050 lbs per cubic yard. This covers most slabs, footings, and foundations poured in the last 50 years.

Reinforced concrete: 155 to 160 lbs per cubic foot. Rebar mats, dowel bars, and wire mesh add steel weight. Most structural concrete is reinforced. Plan on 155 lbs/cu ft for anything with rebar in it.

Lightweight concrete: 110 to 120 lbs per cubic foot. You see this in precast panels, some roof decks, and older commercial tilt-up walls. Less common in slabs and foundations.

Quick conversion: 1 cubic yard of concrete weighs approximately 2 tons. That number gets you close enough for early-stage estimates. For bid-day math, use the exact formulas below.

Estimating Slab Tonnage

Slabs are the most common demo scenario. The formula is simple.

Length (ft) x Width (ft) x Thickness (ft) x 150 lbs/cu ft / 2,000 = tons

The only variable most guys miss is thickness. Here are common slab thicknesses by application:

• Residential driveway: 4 inches (0.33 ft)
• Residential garage: 4 to 6 inches
• Commercial parking lot: 6 to 8 inches
• Warehouse floor: 6 to 10 inches
• Industrial floor: 8 to 12 inches

Quick rule of thumb per 1,000 sq ft:

• 4-inch slab: ~25 tons
• 6-inch slab: ~37 tons
• 8-inch slab: ~50 tons

These three numbers will save you math on 90% of slab jobs. Multiply by the number of thousands of square feet and you have your tonnage.

Example: A 20,000 sq ft parking lot with a 6-inch slab. That is 20 x 37 = ~740 tons.

That is a big number. It also means a big crusher. More on equipment sizing below.

Estimating Foundation Tonnage

Foundations have more pieces than slabs. You need to estimate each component separately and add them up.

Continuous footings: Width (ft) x Depth (ft) x Linear feet x 150 / 2,000 = tons. A typical residential footing is 16 inches wide by 8 inches deep. A typical commercial footing runs 24 to 36 inches wide and 12 to 18 inches deep.

Stem walls: Height (ft) x Thickness (ft) x Linear feet x 150 / 2,000 = tons. Most residential stem walls are 8 inches thick and 18 to 24 inches tall above the footing.

Grade beams: Width (ft) x Depth (ft) x Span (ft) x 150 / 2,000 = tons. Grade beams run heavier than standard footings. They are typically 12 to 24 inches wide and 24 to 36 inches deep.

Spread footings (pads): Length (ft) x Width (ft) x Depth (ft) x 150 / 2,000 = tons per pad. Count the number of pads and multiply. Column pads on commercial buildings can weigh 2 to 5 tons each.

Example: A 2,000 sq ft house with a perimeter footing (160 linear feet of 16″ x 8″ footing) plus a 4-inch slab on grade. Footing: 160 x 1.33 x 0.67 x 150 / 2,000 = ~11 tons. Slab: 2,000 x 0.33 x 150 / 2,000 = ~50 tons. In practice, residential slabs often run 3.5 inches rather than a full 4 inches, which brings the slab closer to ~44 tons. Total comes to roughly 55 tons for the full residential tear-out (footing plus slab).

Estimating Block and Masonry Wall Tonnage

CMU walls are heavier than most guys expect. Here are the weights per square foot of wall face for 8-inch block:

• Ungrouted (hollow) 8-inch CMU: ~35 lbs per square foot
• Fully grouted 8-inch CMU: ~85 lbs per square foot
• Partially grouted (most residential): ~45 to 55 lbs per square foot

Know your wall type before you estimate. Fully grouted walls weigh more than twice what hollow walls weigh. Commercial and structural walls are almost always grouted.

Brick veneer adds roughly 40 lbs per square foot when you count the brick, mortar joints, and any grout fill.

Example: An 8-foot-high grouted CMU wall running 200 linear feet around a commercial building. Wall area: 200 x 8 = 1,600 sq ft. Weight: 1,600 x 85 / 2,000 = 68 tons.

That is just the walls. Add the foundation underneath and you could be looking at 80 to 100 tons for the full structure.

Common Demo Job Estimates: Quick Reference

Use this table for ballpark estimates before you pull out a tape measure.

Print this table. Stick it in your estimating folder. It will keep you from guessing.

How Tonnage Determines Equipment Size

Once you have your tonnage, you can pick the right crusher. Here is how the two Evortle jaw crusher models line up against common job sizes.

The CT-535 weighs 14,330 lbs. It rides on a tag-along trailer behind a one-ton pickup. Built for residential and small commercial jobs.

The CT-850 weighs 52,910 lbs. It ships on a lowboy. This is a production machine for large commercial and municipal work. For material weight per cubic yard and how much each truck type can actually carry, see our truck payload and material weight guide.

When in doubt, call us with your tonnage estimate and material type. We size it and get you connected with the right equipment. 770-433-2670.

Common Mistakes in Tonnage Estimates

Five mistakes that blow estimates on demo jobs.

1. Forgetting rebar weight. Rebar adds 3 to 7% to the weight of a concrete structure. On a 500-ton job, that is 15 to 35 extra tons. Not a rounding error.

2. Ignoring sub-base material. Most slabs sit on 4 to 6 inches of compacted gravel. When you break out a slab, some of that base comes with it. If you are processing material through a crusher, the gravel adds volume and weight.

3. Not accounting for attached soil. Excavated footings and grade beams come out of the ground with soil clinging to them. Wet clay is heavy. A footer pull that should weigh 10 tons might weigh 13 tons by the time it sits in the pile.

4. Over-estimating by too much. It is better to estimate slightly over than under. But a 50% overestimate means you rented a bigger machine than you needed, or scheduled an extra day you did not use. That costs money.

5. Trusting the plans for slab thickness. A slab drawn at 4 inches on the structural plans is sometimes 5 or 6 inches as built. Concrete crews pour to grade, and grades are not always perfect. Measure the actual thickness at a break point or core hole before you bid. A 2-inch difference on a 10,000 sq ft slab adds 125 tons.

Get the Right Crusher for Your Tonnage

Know your tonnage and material type? GrinderCrusherScreen has connected contractors with the right equipment since 1973. Tell us the job details and we will match you with a crusher.

Call 770-433-2670 or visit the concrete crusher rental page to request a quote. Crushers are available in Tampa, Atlanta, Charlotte, and across the Southeast.

Want to see how on-site crushing compares to hauling on cost? Or need help figuring out concrete disposal costs for your bid? Those guides break down the full dollar math.

Looking to buy instead of rent? Browse concrete crushers for sale on GrinderCrusherScreen.com.

Every stone order starts with the same question: how many tons? Order too little and the truck comes back. Order too much and you pay for material you do not need. The math is straightforward once you know the formula.

This guide covers the tonnage calculation from start to finish. Measurement, cubic yard conversion, material weight factors, depth requirements by application, and worked examples you can plug your numbers into right now.

The Basic Formula

Three measurements. One formula. That is all you need.

Length (ft) x Width (ft) x Depth (ft) / 27 = Cubic Yards

Divide by 27 because there are 27 cubic feet in one cubic yard. Measure length and width in feet. Convert depth from inches to feet by dividing by 12.

Example: A driveway that is 60 feet long, 12 feet wide, and 4 inches deep.

60 x 12 x 0.333 / 27 = 8.88 cubic yards

Round up to 9 cubic yards. Then multiply by the material weight to get tons.

Cubic Yards to Tons: Conversion by Material Type

Not all aggregate weighs the same. Crushed stone is heavier than topsoil. Sand is heavier than gravel. Use the correct weight factor for your material or you will be off by 20% or more.

The quick rule: most crushed stone weighs about 1.3 to 1.4 tons per cubic yard. Use 1.35 tons per cubic yard as a general estimate for crushed limestone. If you are ordering crusher run, use 1.25 because the smaller particles pack tighter with less air space.

Back to the driveway example: 9 cubic yards x 1.35 tons per cubic yard = 12.15 tons. Order 13 tons to account for waste and compaction.

Recommended Depth by Application

Stone depth depends on what it is supporting and whether it is a base layer or a surface layer. Too thin and it fails under load. Too thick and you waste material.

Do not skip the base. A gravel driveway with no base course turns into ruts within a year. Crusher run compacts into a solid base that supports the surface stone. The surface layer provides drainage and the finished look.

Coverage Per Ton by Stone Size

Different stone sizes cover different areas at the same depth because larger stones have more air space between them. This table shows coverage at 2-inch depth, a common surface layer thickness.

Why crusher run covers less: the fine particles fill the gaps between larger stones. Less air space means more weight per square foot. That is also why crusher run compacts better than open-graded stone. It locks together.

Worked Examples: Real Projects, Real Numbers

Four common projects calculated step by step. Plug in your own measurements using the same method.

Example 1: Residential Driveway (60 x 12 ft)

Two layers: 6-inch crusher run base + 2-inch #57 stone surface.

Base layer: 60 x 12 x 0.5 / 27 = 13.33 cubic yards 13.33 x 1.25 tons/cy = 16.67 tons Order: 17 tons crusher run

Surface layer: 60 x 12 x 0.167 / 27 = 4.44 cubic yards 4.44 x 1.35 tons/cy = 6.0 tons Order: 7 tons #57 stone

Total: 24 tons (two deliveries, two materials)

Example 2: Parking Pad (20 x 20 ft)

Single layer: 6-inch crusher run, compacted.

20 x 20 x 0.5 / 27 = 7.41 cubic yards 7.41 x 1.25 = 9.26 tons Order: 10 tons crusher run

Example 3: French Drain (50 ft long x 2 ft wide x 1 ft deep)

50 x 2 x 1 / 27 = 3.70 cubic yards 3.70 x 1.35 = 5.0 tons Order: 6 tons #57 washed stone (add a ton for waste and overfill)

Example 4: Base Course for a Slab (100 x 24 ft at 6-inch depth)

100 x 24 x 0.5 / 27 = 44.44 cubic yards 44.44 x 1.25 = 55.56 tons Order: 57 tons crusher run

At 57 tons, you are looking at three standard dump truck loads (18 to 20 tons each). Confirm with your supplier whether they run tandem or tri-axle trucks so you know the delivery count.

The Waste Factor: How Much Extra to Order

Always order more than the math says. Material gets lost to compaction, spreading, edge spillage, and uneven subgrade.

Standard waste factor: 10%. Multiply your calculated tonnage by 1.10. A 20-ton calculation becomes a 22-ton order.

When to add more:

• Uneven subgrade: 15% waste factor. Dips and hollows eat more material than the average depth suggests. If your subgrade varies by 2 or more inches, add extra.
• Long delivery distance: Order full truckloads when possible. A truck that holds 20 tons costs the same to deliver whether it carries 18 tons or 20 tons. Round up to the nearest full load.
• Compaction: Crusher run loses 15% to 20% of its uncompacted volume when you run a plate compactor or roller over it. Factor this in. If you need 6 inches of compacted depth, place 7 to 8 inches of loose material.

Return policies vary. Some suppliers take back unused stone. Most do not. It is cheaper to have a small pile left over than to schedule a second delivery because you came up short.

Delivery Logistics: Trucks, Loads, and Timing

Stone arrives by dump truck. Know what to expect before the truck shows up.

Hauling stone in your own truck? See how much a yard of gravel weighs and truck payload limits by vehicle for pickup, dump trailer, and dump truck capacity by material type.

Delivery fee: $75 to $200 per load. Most quarries include delivery within a radius (often 15 to 25 miles) and charge per mile beyond. Always ask for the delivered price per ton, not just the material price. A stone that costs $2 less per ton but adds $150 in delivery is not a deal.

Site access matters. Make sure the truck can get in, dump, and get out. A tri-axle dump truck needs a 10-foot-wide path and 40 feet of straight distance to dump safely. Overhead power lines, low branches, and soft ground are all problems. Communicate access restrictions to the quarry when you order.

Producing Your Own Aggregate On-Site

If you have concrete rubble, broken rock, or demolition waste on-site, you can crush it into base aggregate instead of buying stone from a quarry.

A portable jaw crusher turns demo concrete into 3/4-inch minus aggregate suitable for base courses, backfill, pipe bedding, and structural fill. Know your tonnage before you start. The same calculation in this guide tells you how many tons of finished aggregate you need. That number tells you how many tons of rubble to feed through the crusher and how many days of crushing the job requires.

Example math: You need 57 tons of base material for a slab pour. You have 80 tons of broken concrete from the old slab you just demolished. Crush 57 tons of it and stockpile the finished aggregate on-site. Zero delivery trips. Zero material cost.

Use the rental cost calculator on our crusher page to estimate what the crushing would cost. For a deeper look at the process, read our guide to on-site concrete crushing.

Our tonnage estimation guide has formulas for calculating how much concrete you get from slabs, footings, walls, and other common demo scenarios.

Stone Sizes and Grades: Picking the Right Material

Not sure which stone to order? The size determines the application.

#57 stone (3/4 to 1 inch): The most common stone for driveways, drainage, and general construction. Good drainage. Does not compact as tightly as crusher run. Use it for surface layers, French drains, and pipe bedding.

#67 stone (3/4 inch): Slightly more uniform than #57. Used for concrete mix aggregate, drainage backfill, and yard projects.

Crusher run (dense-graded base): A mix of crushed stone and fine particles from dust up to 1.5 inches. Compacts into a solid, stable base. This is the standard sub-base material for driveways, parking lots, and building pads.

Stone dust / screenings: The finest fraction from the crushing process. Used as a leveling layer under pavers, as a filler, and as a top-dressing for paths. Packs very tight when wet and compacted.

For a full breakdown of stone sizes, grades, and applications, see our crushed stone sizes and grades guide. If you are working with crusher run specifically, our crusher run guide covers specs, uses, and installation.

For an overview of how aggregate fits into the broader construction material picture, see our construction aggregate types guide.

Frequently Asked Questions

How many tons in a cubic yard of crushed stone?

Crushed limestone weighs about 1.35 tons per cubic yard. Crushed granite is slightly lighter at 1.30 tons per cubic yard. Crusher run weighs about 1.25 tons per cubic yard. Natural gravel runs heavier at 1.40 tons per cubic yard. These numbers vary by moisture content, source quarry, and gradation, but they are close enough for ordering estimates. Always confirm with your supplier if you are working to tight tolerances.

How deep should stone be for a driveway?

A properly built gravel driveway needs 8 to 12 inches total. That is 6 to 8 inches of compacted crusher run base topped with 2 to 3 inches of surface stone (#57 or #67). The base layer is the structural support. The surface layer provides drainage and a finished appearance. Skipping the base layer or going too thin leads to ruts, potholes, and expensive rework within a year.

How much waste factor should I add?

Add 10% for standard projects with a reasonably flat subgrade. Add 15% if the ground is uneven, soft, or has dips that will consume extra material. If your stone needs to be compacted (crusher run base courses), account for 15% to 20% volume loss from compaction on top of the waste factor. It is always cheaper to have a small surplus than to order a second delivery.

How many tons does a dump truck carry?

A single axle dump truck carries 6 to 8 tons. A tandem axle carries 15 to 18 tons. A tri-axle carries 20 to 24 tons. A tractor-trailer end dump carries 22 to 26 tons. Capacity depends on the truck configuration, local weight limits, and the density of the material. When ordering, ask your supplier what trucks they run so you can calculate how many loads your job requires.

What is the difference between a cubic yard and a ton?

A cubic yard is a measurement of volume: 3 feet long, 3 feet wide, 3 feet tall. It measures how much space material occupies. A ton is a measurement of weight: 2,000 lbs. The relationship between the two depends on the material density. One cubic yard of crushed stone weighs about 1.35 tons. One cubic yard of topsoil weighs about 1.0 ton. You need both measurements because quarries sell by the ton but you plan your project by the cubic yard.

A portable jaw crusher costs $150,000 to $450,000 or more to buy. Renting the same machine runs $7,500 to $12,000 per week. The right choice depends on one number: how many weeks per year you actually run a crusher.

This guide breaks down every cost on both sides of the equation. Purchase price, rental rates, hidden ownership expenses, and the exact utilization threshold where buying beats renting. No theory. Just the math.

What a Portable Crusher Costs to Buy

Portable jaw crushers come in two categories. Compact models for residential and small commercial work, and production machines for high-volume demo and recycling operations.

Compact jaw crushers: $150,000 to $220,000. Machines in the 14,000 to 25,000 lb range. The Evortle CT-535 sits in this class at 14,330 lbs with a 20×14-inch jaw opening. These units tow behind a one-ton pickup on a standard tag-along trailer. They handle jobs under 200 tons and fit through residential gates and into tight sites.

Production jaw crushers: $350,000 to $500,000+. Machines from 40,000 to 65,000 lbs. The Evortle CT-850 falls here at 52,910 lbs with a 32×20-inch jaw opening. These ship on a lowboy and process 65 to 130 tons per hour. Built for commercial demo, municipal recycling, and high-volume concrete processing.

Used market pricing: 40% to 60% of new. A five-year-old compact crusher in good condition sells for $90,000 to $130,000. A used production machine runs $150,000 to $240,000 depending on hours, jaw wear, and overall condition. GCS sells both new and used portable crushers. Browse available crushers here.

But the sticker price is only the beginning. Ownership costs stack up fast once the machine hits your yard.

Total Cost of Ownership: What You Actually Pay

Purchase price gets you the machine. Keeping it running costs another 8% to 12% of the purchase price every year. Here is where that money goes.

Jaw plates are the big consumable. They wear based on material hardness, feed rate, and CSS setting. Crushing reinforced concrete wears jaws faster than plain concrete or block. Most contractors replace jaw plates every 400 to 800 operating hours on a compact machine and every 600 to 1,000 hours on a production unit. Budget for one to two jaw sets per year if you run regularly.

Maintenance is not optional. Hydraulic hoses, bearings, toggle plates, conveyor belts, and electrical components all need scheduled service. Skip it and you pay double in emergency repairs and unplanned downtime. A crusher sitting broken in your yard does not make money.

Insurance covers the asset, not the income. Equipment insurance runs 2% to 3% of the machine value annually. That protects against theft, fire, and catastrophic damage. It does not cover lost revenue when the machine is down for repairs.

Transport adds up fast. A compact crusher on a tag-along trailer costs $500 to $1,200 per move. A production machine on a lowboy runs $2,500 to $4,500 depending on distance. If you are mobilizing to a new site every two weeks, transport costs $13,000 to $60,000 per year.

What Crusher Rentals Cost

Rental rates vary by machine size, rental duration, and region. Here is what contractors pay in the current market.

What is included in a typical rental:

• The crusher, ready to run
• Delivery to your job site and pickup when you are done
• Basic orientation on operation and safety
• Wear parts for normal use during the rental period

What is not included:

• Fuel (you supply diesel)
• Feeding equipment (excavator or skid steer to load the hopper)
• Operator (most rentals are operated by your crew)
• Excessive wear or damage beyond normal use

Longer rentals drop the weekly rate. A four-week rental typically costs 75% to 85% of the straight weekly rate multiplied by four. If you know you need the machine for a month, negotiate the monthly rate upfront.

GCS connects contractors with rental crushers delivered to your site. One call gets you a machine sized to your job.

The Break-Even Math: When Buying Beats Renting

This is the number that matters. How many weeks per year of crusher use before ownership costs less than renting?

The table below compares annual costs at different utilization rates. Ownership costs include the machine payment (financed over 5 years at 7%), maintenance, insurance, and two transport mobilizations. Rental costs assume weekly rates with delivery included.

Compact Crusher: Annual Cost by Utilization

Production Crusher: Annual Cost by Utilization

The compact crusher break-even: 6 to 8 weeks per year. If you run a compact jaw crusher more than 8 weeks per year, buying is cheaper. At 12 weeks, ownership saves you $38,500 annually. At 20 weeks, the gap is $97,000.

The production crusher break-even: 14 to 16 weeks per year. The higher purchase price and maintenance costs push the crossover point further out. Below 14 weeks of annual use, renting wins. Above 16, buying starts saving serious money.

The nuance most calculators miss: ownership cost per week drops as utilization goes up, but maintenance costs increase with hours. The table above accounts for incremental maintenance tied to operating hours. A machine running 40 weeks a year needs jaw plates, hydraulic service, and general maintenance that a 4-week machine does not.

Hidden Costs Most Buyers Forget

The break-even math looks clean on paper. In practice, several costs sneak in that tip the scales.

Downtime kills your schedule. When a rental breaks down, the rental provider handles it. They bring a replacement or fix it on-site. When your machine breaks down, you wait for parts, schedule a mechanic, and lose days of production. One hydraulic pump failure can shut you down for two weeks.

Technology moves fast. Crusher technology improves every few years. New models run quieter, burn less fuel, and process faster. When you rent, you always get current equipment. When you own, you are locked into whatever you bought until you sell it and upgrade.

Capital is tied up. $156,000 to $450,000 in a crusher is $156,000 to $450,000 not available for other equipment, trucks, or working capital. For contractors who are growing, the opportunity cost of tying up capital in a crusher matters.

Resale value is uncertain. Crushers hold value better than most heavy equipment, but the used market fluctuates. A machine you paid $450,000 for might sell for $225,000 in five years or $270,000. You do not know until you list it. GCS handles used equipment sales for contractors looking to sell. The process is free to the seller.

When Renting Is the Right Call

Renting makes sense in these situations:

Project-based work. You land a 500-ton demo job, crush the concrete, and move on. No need to own a machine that sits idle between jobs. Rent it for the project, return it, and pay nothing when it is not working.

Testing the market. You are thinking about adding on-site crushing as a service line. Rent a crusher for a few jobs, learn the workflow, see if your customers want it, and then decide whether to buy.

Overflow capacity. You own a compact crusher and land a job that needs a production machine. Rent the larger unit for the big job and keep running your own machine on smaller work.

Seasonal work. Crushing season in northern states is 20 to 30 weeks. If you only need a machine during the warm months and your utilization falls below the break-even point, renting saves money.

When Buying Is the Right Call

Buying makes sense when:

You run a crusher more than 8 to 16 weeks per year. Once you cross the break-even threshold, every additional week of use saves you money compared to renting. A contractor running 30 weeks per year saves $150,000+ annually by owning.

You crush on every job. Demolition contractors, site-prep companies, and recycling operators who process concrete on most projects get the highest utilization. If the crusher is part of your daily workflow, own it.

You want to sell the aggregate. Recycled aggregate sells for $8 to $15 per ton in most markets. If you are producing material to sell, the crusher is a revenue-generating asset, not just a cost-saving tool. Ownership puts all that margin in your pocket. See how concrete recycling works for the full process.

You need the machine available on demand. Rental availability varies, especially during peak season. Owning means the machine is in your yard when you need it. No waiting, no scheduling around someone else’s calendar.

GCS Handles Both Sides

GCS sells new and used portable crushers for contractors who run them year-round. The Evortle CT-535 and CT-850 cover everything from residential tear-outs to large-scale commercial demo. GCS also helps line up financing to spread the cost over time.

For project-based work, GCS connects you with rental equipment delivered to your site. Pick the machine size, get a quote, and we coordinate delivery and pickup.

One call handles either option. 770-433-2670. Since 1973.

What Types of Crushers Are Available?

This guide focuses on jaw crushers because they handle the majority of concrete crushing work. But jaw crushers are not the only option. Impact crushers, cone crushers, and combination units each serve different applications. Our complete guide to crusher types covers the differences.

One important note: jaw crushers do not process asphalt. Asphalt requires an impact crusher with a different crushing action. If your project involves asphalt milling or recycling, that is a separate equipment conversation.

Cost Savings Beyond the Machine

Whether you rent or buy, portable crushing saves money in ways that go beyond the machine cost.

Eliminated tipping fees: $15 to $55 per ton. No trips to the landfill means no gate charges. On a 500-ton job at $35/ton, that is $17,500 you keep.

Eliminated trucking: $4 to $6 per loaded mile. No haul trips means no truck fuel, no driver time, no waiting at the scale house. A 500-ton job that would take 25 truckloads saves $2,500 to $3,750 in trucking costs alone. See the full hauling vs. crushing cost comparison.

Free base material. The crushed output is 3/4-inch minus aggregate suitable for road base, backfill, and pipe bedding. Instead of paying $12 to $18 per ton for delivered aggregate, you produce it on-site from material you already have.

Frequently Asked Questions

What does a portable crusher cost to buy?

Compact portable jaw crushers (under 20,000 lbs) cost $150,000 to $220,000 new. Production machines (40,000 to 65,000 lbs) run $350,000 to $500,000+. Used models sell for 40% to 60% of new pricing depending on hours, condition, and age. GCS sells both new and used crushers and helps line up financing.

How many weeks per year before buying pays off?

For compact jaw crushers, the break-even point is 6 to 8 weeks of use per year. For production machines, it is 14 to 16 weeks. Below that, renting is cheaper. Above that, ownership saves more money each additional week you run the machine. The exact number depends on your purchase price, financing terms, and local rental rates.

Can I rent a crusher with an operator?

Some rental providers include an operator option at an additional daily rate, typically $400 to $600 per day on top of the equipment rental. Most contractors run the machine with their own crew. Jaw crushers are not complicated to operate. GCS can connect you with rental providers who offer operator-assisted packages if you need them.

What is included in a crusher rental?

A standard crusher rental includes the machine, delivery to your job site, pickup when you are done, and a basic operational orientation. You supply fuel, a feeding machine (excavator or skid steer), and an operator. Wear parts for normal use during the rental period are typically covered. Excessive wear or damage beyond normal use is your responsibility.

Can I try a rental before deciding to buy?

Yes. Contractors regularly rent a crusher for one or two jobs to test the workflow, measure throughput, and confirm the business case before committing to a purchase. This is the lowest-risk way to evaluate whether crushing fits your operation. Run the numbers from your actual job and compare them to the ownership math in this guide. When you are ready to buy, GCS carries new and used models and helps arrange financing.

Aggregate is the backbone of construction. Roads, foundations, drainage systems, concrete mix, parking lots, and building pads all sit on or contain aggregate. By volume, it is the single most consumed construction material on earth. The United States alone uses roughly 2.5 billion tons of construction aggregate per year, according to USGS Mineral Commodity Summaries.

Most contractors buy aggregate from a quarry or supply yard. But every demolition project also produces raw material for aggregate. A jaw crusher turns concrete rubble into sized aggregate on-site. A vibratory screener separates it into spec products you can reuse or sell.

This guide covers all three aggregate types: natural, manufactured, and recycled. What each one is, how it is produced, standard sizes, and where each type gets used in the field.

What Is Construction Aggregate?

Construction aggregate is any granular material used as a component in construction. Sand, gravel, crushed stone, slag, recycled concrete, and manufactured stone all qualify. The common thread: sized, inert particles that provide bulk, strength, drainage, or structure when placed and compacted.

Aggregate serves two basic functions:

Structural: It distributes load and provides a stable base. Road base, sub-base, foundation pads, and backfill all rely on aggregate to transfer weight to the subgrade without settling or shifting.

Volumetric: In concrete and asphalt mix, aggregate makes up 60-80% of the total volume. It provides bulk and hardness while cement or asphalt binder holds the particles together.

The quality of the aggregate determines the quality of the finished product. Weak stone makes weak roads. Dirty aggregate makes bad concrete. Poorly graded base course fails under load. Everything downstream depends on the aggregate spec being right.

Three Types of Construction Aggregate

All aggregate falls into one of three categories based on its source and how it is processed.

Natural Aggregate

Mined directly from the earth. Pit-run gravel, river rock, and sand are natural aggregates. They form through geological processes: weathering, erosion, glacial deposits, and alluvial flows.

How it is produced: Extracted from open pits, riverbeds, or underwater deposits. Minimal processing. Washed and screened to remove clay, silt, and organic material, then sorted by size. No crushing required for rounded gravel and sand. Angular pit-run material may go through a primary crusher to produce specific sizes.

Characteristics: Rounded or sub-rounded particles (river gravel). Lower interlock than crushed stone because smooth surfaces do not grip as tightly. Excellent for drainage, concrete mix, and landscaping. Less ideal for road base where particle interlock matters.

Cost: $8-$20 per ton at the quarry gate, depending on size and region.

Manufactured (Crushed) Aggregate

Quarried rock run through crushers and screens to produce angular, sized particles. Limestone, granite, basalt, dolomite, and trap rock are the most common source stones.

How it is produced: Blasting breaks solid rock from the quarry face. Primary jaw crushers reduce the blasted rock from boulders to fist-sized pieces. Secondary crushers (cone or impact) reduce it further. Multi-deck vibrating screens sort the output into sized fractions: #57 stone, #67 stone, #8 stone, screenings, and other gradations.

Characteristics: Angular, fractured surfaces. High interlock when compacted. Superior load-bearing capacity compared to rounded natural aggregate. The standard material for road base, sub-base, concrete mix, and structural applications.

Cost: $12-$30 per ton at the quarry, depending on rock type and size.

Recycled Aggregate

Demolished concrete, brick, block, and masonry processed through a crusher and screen. Also called recycled concrete aggregate (RCA) when the source is concrete.

How it is produced: Demolition debris is collected, sorted to remove contaminants (wood, drywall, plastic), and fed through a jaw crusher. An overband magnet removes rebar and steel during processing. The crusher output is screened into sized fractions. See our complete concrete recycling process guide for the step-by-step walkthrough.

Characteristics: Angular particles similar to crushed stone. Slightly higher water absorption than virgin aggregate (4-8% vs. 1-3%). LA Abrasion loss typically 30-45%. Meets DOT base course specifications in all Southeast states. Accepted for concrete mix aggregate at limited percentages (20-30%) in most states.

Cost: $6-$15 per ton purchased. $5-$12 per ton self-produced with portable equipment.

Aggregate Type Comparison Matrix

The cost advantage of recycled aggregate is clear. At $6-$15 per ton purchased (or $5-$12 self-produced), RCA runs 40-60% cheaper than virgin crushed stone. For base course, backfill, and pipe bedding, the performance is equivalent.

Standard Aggregate Sizes and Gradations

Aggregate sizing follows ASTM and AASHTO designation systems. Each number corresponds to a specific sieve analysis (the percentage of material that passes through each screen size). Here are the sizes contractors encounter most often.

Crusher run is the most used aggregate product in site work. It is the full output of a crusher: a blend of all sizes from the CSS maximum down to dust. The range of particle sizes interlocks and compacts into a dense, stable base. Most road base, driveway base, and parking lot sub-base specs call for crusher run or dense-grade aggregate.

For a deeper breakdown of sizes and what each one does, see our crushed stone sizes and grades guide.

How Aggregate Is Made: The Production Process

Whether the source is quarried rock or demolished concrete, the production process follows the same basic sequence: reduce, separate, stockpile.

Quarry Production (Manufactured Aggregate)

1. Drilling and blasting: Drill rigs bore holes into the quarry face. Explosives fracture the rock into manageable boulders. 2. Primary crushing: A jaw crusher reduces boulders from 3-4 feet down to 6-8 inches. Jaw crushers use compressive force: two steel plates (jaws) squeeze and crack the rock. 3. Secondary crushing: A cone crusher or impact crusher further reduces the material to finished sizes. Cone crushers produce cubical particles. Impact crushers produce more angular shapes. 4. Screening: Multi-deck vibrating screens sort the crushed output into sized fractions. Each deck has a different screen opening. Material passes through screens from top to bottom, with the largest sizes caught on upper decks and fines falling to the bottom. 5. Washing (optional): Some aggregate products are washed to remove clay, dust, and fines. Washed stone commands a premium price for concrete mix and decorative applications. 6. Stockpiling: Sized products are conveyed to separate stockpile areas. Wheel loaders fill trucks from each pile as orders come in.

On-Site Production (Recycled Aggregate)

Contractors can produce aggregate directly on demolition sites using portable equipment. The process is simpler than quarry production because demo concrete is already partially broken.

1. Demolition and sorting: Excavator breaks the structure and separates concrete from other debris. 2. Feeding: Excavator or wheel loader feeds broken concrete into a portable jaw crusher. 3. Crushing: The jaw crusher reduces concrete to the CSS target size. Integrated overband magnet removes rebar. 4. Screening (optional): A vibratory screener separates the crusher output into sized fractions. Skip this step if crusher run (full-range mix) is the target product. 5. Stockpiling: Sized aggregate is staged for immediate reuse on the same project or loaded for transport to other sites.

The difference: A quarry runs permanently at one location with stationary equipment worth millions. On-site recycling is temporary, using portable machines that set up in hours and move to the next job. The output quality is comparable when proper gradation control is maintained. For the full on-site crushing walkthrough, see our process and cost guide.

Applications by Project Type

Different projects need different aggregate products. This table maps the most common project types to the aggregate products they consume.

Aggregate Testing: How Quality Is Verified

Aggregate is only as good as its test results. Three tests are standard across the industry.

Sieve analysis (ASTM C136): The most common test. A stack of progressively finer sieves shakes for a set time. The percentage of material retained on each sieve defines the gradation curve. Every DOT spec and concrete mix design references a sieve analysis. If the gradation falls outside the spec envelope, the material fails.

LA Abrasion (ASTM C131): Measures hardness. Steel balls rotate with aggregate samples in a drum. The percentage of material that breaks down to fines after 500 revolutions is the abrasion loss. Lower numbers mean harder stone. Most specs allow a maximum of 40-50% loss. Granite typically scores 15-25%. Limestone runs 20-35%. Recycled concrete aggregate hits 30-45%.

Specific gravity and absorption (ASTM C127/C128): Determines density and how much water the aggregate absorbs. High absorption affects concrete mix water ratios and freeze-thaw durability. Virgin crushed stone absorbs 1-3%. Recycled aggregate absorbs 4-8%.

When testing matters: DOT projects, commercial concrete mix, and any specification that references ASTM or AASHTO standards. For backfill, fill, and general site work, visual inspection and a proctor compaction test are often sufficient.

Producing Your Own Aggregate On-Site

Every demolition project creates feed material for aggregate production. A 2,000-square-foot concrete slab at 4 inches thick weighs roughly 50 tons. That is 50 tons of crusher run or sized aggregate waiting to be produced instead of hauled to a landfill at $25 to $80 per ton.

What you need:

• A jaw crusher. The Evortle CT-535 handles jobs under 200 tons. The Evortle CT-850 runs production pace on larger commercial work. Both process concrete, rock, brick, and block. Neither processes asphalt (that needs an impact crusher; see our crusher types guide).
• A vibratory screener (optional). If you need sized fractions instead of crusher run, a vibratory screener separates the crusher output. Skip the screen if full-range crusher run is the target.
• An excavator or wheel loader. To feed the crusher and manage stockpiles. Most demo sites already have one on-site.

The math works at 50 tons and above. Below 50 tons, buying aggregate from a supplier is typically cheaper than mobilizing a crusher. Above 50 tons, on-site production saves money on both disposal (no haul-out cost) and material (no aggregate purchase). At 200 tons, contractors typically save $5,000 to $10,000 compared to hauling out and buying back aggregate.

GrinderCrusherScreen connects contractors with portable crushing and screening equipment across the Southeast. Call 770-433-2670 to talk through your project and get matched with the right equipment. We have been in the equipment business since 1973.

Frequently Asked Questions

Aggregate vs gravel: what is the difference?

Gravel is one type of aggregate. All gravel is aggregate, but not all aggregate is gravel. Gravel refers specifically to naturally occurring rounded rock particles, typically from riverbeds or glacial deposits. Aggregate is the broader term that includes gravel, crushed stone, sand, slag, recycled concrete, and manufactured stone. When a spec calls for “aggregate,” it defines the exact gradation and properties needed. When someone says “gravel,” they usually mean rounded natural stone, though the term is used loosely in everyday conversation.

What is fine vs coarse aggregate?

Coarse aggregate is material retained on a No. 4 sieve (particles larger than 0.187 inches, roughly 3/16 of an inch). Fine aggregate passes through a No. 4 sieve. Sand is the most common fine aggregate. In concrete mix design, the ratio of coarse to fine aggregate affects workability, strength, and finish quality. A typical structural concrete mix uses roughly 60% coarse aggregate and 40% fine aggregate by weight, combined with cement and water.

Can you make aggregate from demolition concrete?

Yes. A jaw crusher processes demolished concrete into recycled concrete aggregate (RCA) that meets base course specifications in all Southeast states. The crusher reduces concrete slabs, walls, and footings to a target size set by the CSS (closed-side setting). An integrated magnet removes rebar. The output is structurally sound aggregate usable for road base, sub-base, backfill, pipe bedding, and structural fill. For a full walkthrough, see our concrete recycling process guide.

What is the most common aggregate size?

Crusher run (dense-grade aggregate) and #57 stone are the two most common aggregate products in construction. Crusher run is the default for base course, driveway construction, and sub-base layers because its blend of sizes from 1.5 inches to dust compacts into a dense, stable pad. #57 stone (1 inch to No. 4 sieve) is the standard for concrete mix, drainage, and backfill. Together, these two products account for the majority of aggregate consumed on construction sites. See our stone sizes guide for a full reference.

How is aggregate tested?

Three standard tests cover most applications. Sieve analysis (ASTM C136) measures gradation: the distribution of particle sizes. Every DOT and concrete spec references a gradation curve. LA Abrasion (ASTM C131) measures hardness by tumbling aggregate with steel balls and measuring the breakdown. Specific gravity and absorption (ASTM C127/C128) measures density and water uptake. For DOT base course, sieve analysis is the critical test. For concrete mix, all three tests apply. Testing is performed by certified labs and costs $100 to $300 per sample depending on the test suite.

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Stop buying what you can produce. Every demolition project generates raw aggregate material. A portable jaw crusher and vibratory screener turn that rubble into spec product on-site, eliminating both disposal costs and aggregate purchase costs.

Browse concrete crushers on the GrinderCrusherScreen main site or check the crusher rental page for availability in your area. Call 770-433-2670. Since 1973.

The EPA estimates 600 million tons of C&D debris hit the waste stream every year in the United States. Concrete makes up the biggest share by weight. Most of it still goes to landfills at $25 to $80 per ton in disposal costs.

That concrete is not waste. It is raw material. A jaw crusher and a vibratory screener turn demolished concrete into recycled concrete aggregate (RCA): sized, graded base material that meets DOT spec for road construction, backfill, pipe bedding, and structural fill. The process works at fixed recycling plants and directly on the demo site with portable equipment.

This guide walks through every step of concrete recycling, from demolition to finished product. Costs, equipment, environmental numbers, and state DOT acceptance are all covered.

Step 1: Demolition and Collection

Concrete recycling starts the moment the excavator pulls its first slab. The material needs to be broken into feed-sized pieces before it hits a crusher.

Hydraulic breakers mounted on excavators crack slabs, footings, and walls into chunks small enough for the crusher jaw opening. For a compact jaw crusher like the Evortle CT-535, that means pieces under 20 inches across. For a production machine like the Evortle CT-850, the jaw accepts material up to 32 inches wide.

Sorting happens at the pile. Excavator operators separate concrete from wood, drywall, roofing, and other C&D waste streams. Clean concrete (no contaminants, no mixed debris) produces the best aggregate and commands the highest reuse value. Mixed loads with soil, wood, or trash require more screening passes and produce lower-grade output.

Stockpile the feed material. The excavator stages broken concrete in a feed pile near the crusher. On large jobs, this pile grows continuously as demolition progresses. On smaller jobs, the full teardown may happen before crushing starts.

Step 2: Rebar Removal and Pre-Processing

Reinforced concrete has steel rebar embedded in it. Every commercial foundation, bridge deck, and structural wall contains reinforcement. That steel needs to come out before the aggregate is usable.

Two methods handle rebar removal:

Overband magnets on jaw crushers pull rebar, tie wire, and steel fragments from the crushed material automatically during processing. The CT-850 includes the magnet as standard equipment; on the CT-535, it is an available option. The magnet sits above the discharge conveyor. As crushed material exits the jaw chamber, the magnet grabs ferrous metal and drops it into a separate scrap pile. This is the standard method on portable crushing operations.

Manual pre-processing involves cutting exposed rebar with a torch or hydraulic shears before material enters the crusher. This adds labor time but reduces wear on jaw plates. On jobs with heavy reinforcement (number 8 bar and above, or post-tensioned cable), pre-cutting rebar improves feed rate and extends jaw liner life.

The scrap steel has value. Ferrous scrap prices fluctuate, but rebar pulled from a concrete recycling operation typically sells for $150 to $250 per ton to local scrap yards. On a 500-ton concrete job with 2% steel content by weight, that is 10 tons of rebar worth $1,500 to $2,500 in scrap revenue.

Step 3: Primary Crushing

This is where concrete becomes aggregate.

The excavator or wheel loader feeds broken concrete into the crusher hopper. Jaw plates close on the material and crush it to the set CSS (closed-side setting). CSS controls the maximum particle size in the output. Set the CSS to 0.8 inch on the CT-535 for road base aggregate. The CT-850 produces 1-inch minus material at its tightest setting. Open the CSS to 1.5 inches on either machine for larger base material.

Jaw crushers handle concrete, rock, brick, block, and masonry. They do not process asphalt. Asphalt requires an impact crusher, which uses a different crushing action. See our crusher types guide for the full breakdown on jaw vs. impact vs. cone crushers.

Two equipment tiers cover most recycling volumes:

Not sure which model fits your project? Estimate your tonnage first using our demolition sizing guide.

Throughput depends on three things: material hardness, rebar density, and feed consistency. Clean unreinforced concrete crushes faster than heavily reinforced structural walls. Consistent feed sizes (no oversized chunks jamming the chamber) keep production steady. An experienced excavator operator who manages the feed rate makes a measurable difference in daily output.

Step 4: Screening and Grading

Raw crusher output is a mix of particle sizes from dust to the CSS maximum. For many applications (road base, backfill, haul roads), this crusher run material works as-is. The blend of fine and coarse particles interlocks and compacts well.

For spec work that requires specific gradations, screening separates the crusher output into sized products.

A vibratory screener takes the crusher output and sorts it across two screen decks into three size fractions. Common separations:

• 3/4-inch clean: Coarse aggregate for concrete mix, drainage layer, and structural applications
• 3/8-inch clean: Fine aggregate for concrete mix, bedding, and surface course
• Minus 3/8-inch fines: Fill material, base fines, and blending stock

Each fraction has a different market value and a different set of end uses. Screening adds a processing step but creates multiple saleable products from a single feed source.

Gradation matters for DOT work. State DOT specifications define exact sieve analysis requirements for base course, sub-base, and aggregate products. Running a crusher and screen together lets you hit those gradation targets on-site. Refer to our crushed stone sizes guide for standard size designations.

Step 5: Stockpiling and Quality Control

Crushed and screened material goes to stockpile areas organized by product size. Proper stockpiling prevents contamination between grades and keeps the product clean for end use.

Stockpile management basics:

• Separate each product grade with at least 10 feet of clearance
• Build conical piles, not flat windrows (less surface area exposed to rain and contamination)
• Keep stockpiles on clean, compacted ground or geotextile fabric
• Label each pile with size designation and test date

Testing and spec compliance matter when selling aggregate or using it on DOT projects. Standard tests include:

• Sieve analysis (ASTM C136): Confirms gradation meets target specification
• LA Abrasion (ASTM C131): Measures hardness and durability. RCA typically scores 30-45% loss (spec maximum is usually 50%)
• Soundness (ASTM C88): Tests resistance to freeze-thaw cycles
• Specific gravity and absorption (ASTM C127/C128): RCA absorbs more water than virgin aggregate (typically 4-8% vs. 1-3%). This affects concrete mix design ratios.

For base course and backfill applications, sieve analysis alone is usually sufficient. For concrete mix aggregate, the full test suite applies.

Fixed-Plant vs. Portable On-Site Recycling

Concrete recycling operations run two ways. The economics are different for each.

Fixed-Plant Recycling Yards

Permanent facilities with stationary crushers, multi-deck screens, stockpile areas, and scale houses. Contractors haul demolition concrete to the yard, pay a reduced tipping fee ($8 to $15 per ton vs. $25 to $55 at a C&D landfill), and the facility processes it into graded products for resale.

Pros: No equipment rental needed. Drive in, dump, leave. Works for small jobs where mobilizing a crusher does not make economic sense.

Cons: You still pay trucking and tipping fees. You lose the material value (the recycling yard keeps the aggregate). Wait times during peak hours cost you driver time. And you need a recycling yard within economical haul distance of your site.

Portable On-Site Crushing

A jaw crusher and vibratory screener come to your demo site. You process the concrete where it sits. No trucks leave the site. No tipping fees. The aggregate stays on your project.

Pros: Zero haul trips. Zero disposal fees. You keep the aggregate for backfill, base course, or resale. Works on any site with enough space for the crusher footprint.

Cons: Equipment rental cost. Need an excavator or loader to feed the crusher. Requires space for the crusher, screen, and stockpiles. Minimum volume of around 50 tons to break even vs. hauling.

For a full cost comparison, see our on-site crushing process and cost guide.

Recycled vs. Virgin Aggregate: Side-by-Side Comparison

The key difference: RCA absorbs more water and has slightly lower abrasion resistance. For base course, sub-base, and fill applications, these differences do not affect performance. For structural concrete mix, most specs limit RCA to 20-30% of total aggregate content.

State DOT Acceptance: Southeast States

Every state DOT has its own specifications for recycled concrete aggregate. Acceptance varies by application. Here is where SE states stand.

All six SE states accept RCA for base course work, which is the most common end use for recycled concrete on contractor jobsites. For structural concrete mix applications, state policies differ. Check the current edition of your state DOT standard specifications before bidding work that depends on RCA acceptance.

Environmental Impact of Concrete Recycling

Concrete recycling has measurable environmental benefits. These numbers matter for LEED certification, green building compliance, and increasingly for public bid scoring.

The real environmental win is eliminating truck trips. A 500-ton demo job hauled out at 20 tons per truck is 25 round trips. At an average 25-mile distance, that is 1,250 miles of truck travel eliminated. At roughly 6 miles per gallon for a loaded tri-axle, that is 208 gallons of diesel saved on trucking alone.

What Concrete Recycling Costs

The cost depends on whether you haul to a recycling facility or process on-site.

Hauling to a recycling yard:

• Tipping fee at the recycling facility: $8-$15/ton (lower than C&D landfill rates)
• Trucking: $5-$8/ton (varies by haul distance)
• Loading and staging: $2-$4/ton
• Total: $15-$27/ton

On-site portable crushing:

• Equipment rental (crusher): varies by model and market
• Equipment rental (vibratory screener, if needed): varies
• Fuel: varies by material hardness and hours run
• Operator (if not using existing crew): varies
• Total: $5-$12/ton (see full breakdown in our on-site crushing cost guide)

Value of the recycled product:

• RCA base material sells for $6-$15/ton at recycling yards
• Self-produced RCA replaces purchased virgin aggregate at $15-$30/ton
• Scrap rebar recovery: $150-$250/ton of steel

On a 300-ton commercial demo job in Atlanta, on-site crushing at $8/ton costs $2,400 to process. That same 300 tons would cost $12,000 to $24,000 to haul and dump at a C&D landfill. And you keep the aggregate on-site instead of buying $6,000 worth of new base material.

The break-even point for on-site crushing sits around 50 tons. Below that, hauling to a nearby recycling yard is usually cheaper. Above 50 tons, the economics tip sharply toward on-site processing. For detailed math at different job sizes, see our disposal cost comparison.

The Step-by-Step Process: Summary Table

LEED and Green Building Credits

Concrete recycling directly contributes to LEED certification under the Materials and Resources (MR) category. In LEED v4.1, the Construction and Demolition Waste Management credit rewards projects that divert C&D waste from landfills.

Two paths to credit:

• Path 1 (Diversion): Divert 50% of total C&D waste (by weight) for 1 point. Divert 75% for 2 points. On-site concrete recycling counts 100% toward diversion because the material never leaves the site.
• Path 2 (Reduction): Reduce total C&D waste generation below an established limit. Less common on demo projects but applicable on new construction.

For contractors bidding LEED-certified projects, on-site concrete recycling is one of the easiest MR credits to earn. The documentation is straightforward: weigh your feed material, weigh your output, document the reuse. No third-party recycling facility records needed when you process on-site.

Frequently Asked Questions

Is recycled concrete as strong as virgin aggregate?

For base course and sub-base, yes. RCA compacts and performs at equivalent levels to virgin crushed stone when properly graded. The California Bearing Ratio (CBR) for well-graded RCA typically exceeds 80%, which meets or exceeds most DOT base course specifications. For structural concrete mix, RCA is approved in limited percentages (typically 20-30% of total aggregate) because its higher water absorption affects the water-cement ratio.

Can recycled concrete go under a building?

Yes. Recycled concrete aggregate is approved for structural backfill and foundation sub-base in all six SE states. It compacts to 95%+ Modified Proctor density, which meets standard structural fill requirements. Many commercial and residential foundations sit on RCA base course. The key is proper gradation and compaction testing, the same requirements that apply to virgin aggregate.

What about rebar in the concrete?

Jaw crushers process rebar-reinforced concrete without issues. An overband magnet pulls steel from the crushed output automatically (standard on the CT-850, optional on the CT-535). The steel goes to a scrap pile and the aggregate exits clean. Heavy rebar (number 8 and above) slows the feed rate and increases jaw liner wear, but the machine handles it. Pre-cutting exposed rebar on heavily reinforced material reduces wear and improves throughput.

How much does recycled concrete cost?

Three price points depending on how you get it. Purchased from a recycling yard: $6 to $15 per ton. Self-produced on-site with portable crushing equipment: $5 to $12 per ton processing cost. Hauled to a recycling facility for disposal: $15 to $27 per ton all-in (tipping plus trucking). The cheapest option is producing it yourself on jobs over 50 tons. See our concrete disposal cost guide for the full math.

Do DOTs accept recycled concrete aggregate?

Yes. All six Southeast states (GA, FL, NC, SC, TN, AL) accept RCA for base course, sub-base, and pipe bedding. Acceptance for structural concrete mix aggregate varies by state and typically allows RCA at 20-30% of total aggregate content. Always check the current edition of your state DOT standard specifications. Acceptance criteria include sieve analysis, LA Abrasion, and soundness testing. See the state acceptance table above for specific spec references.

Can you sell recycled aggregate?

Yes. Contractors who produce more RCA than they need on a job sell the surplus to neighboring projects, landscaping suppliers, and aggregate yards. Market price for RCA ranges from $6 to $15 per ton, depending on gradation and local supply. Clean, well-graded 3/4-inch base material commands the highest price. This turns a disposal cost into a revenue stream. Some contractors run concrete recycling as a side business, processing rubble from other demo companies and selling the output.

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Skip the recycling yard. A portable jaw crusher and vibratory screener on your demo site turn concrete rubble into DOT-spec base material. No haul trips. No tipping fees. No waiting in line at the transfer station.

GrinderCrusherScreen connects contractors with portable crushing and screening equipment across the Southeast. Browse concrete crushers on our main site or check rental availability on the crusher rental page. Call 770-433-2670 to talk through your project. We have been matching contractors with the right equipment since 1973.

A trommel screen is a rotating drum with sized mesh panels that separates material by particle size. Mixed material goes in one end. As the drum spins, small particles fall through the mesh openings. Larger particles tumble forward through the drum and discharge off the far end. One machine, one pass, two or three clean stockpiles.

Contractors and material producers use trommels to screen topsoil, compost, mulch, sand, woodchips, and C&D fines. The machine replaces hand-sorting, multiple passes through static screens, and the old method of hauling mixed material off-site for someone else to process.

How a Trommel Screen Works: Step by Step

The operating principle is simple. A steel drum (typically 4 to 6 feet in diameter and 7 to 16 feet long) sits on a slight incline, higher at the feed end. The drum rotates at 14 to 20 RPM. Mesh panels line the inside of the drum in one or two screen sections, each with different-sized openings.

Step 1: Feed the hopper. A loader or excavator dumps mixed material into a feed hopper at the elevated end of the trommel. An apron or belt feeder meters the material into the drum at a controlled rate. Overloading the drum reduces screening efficiency. A steady, even feed produces the cleanest product.

Step 2: The drum rotates and tumbles. As the drum spins, material lifts partway up the drum wall, then cascades back down through the air. This tumbling action breaks up clumps, exposes every particle to the mesh openings, and keeps the screen self-cleaning. Stuck material shakes loose with each revolution. That self-cleaning action is one reason trommels outperform flat screens on wet and sticky material.

Step 3: Fines fall through. The first mesh section has the smallest openings (1/4 inch to 3/4 inch for most applications). Fine particles drop through and land on a conveyor belt below the drum. That belt carries the fines to a stockpile: your finished product if you are screening topsoil or compost.

Step 4: Mid-size product sorts next. If the trommel has a second mesh section with larger openings, mid-size particles fall through to a separate conveyor and stockpile. This gives you a second graded product from the same pass.

Step 5: Oversize discharges off the end. Everything too large to pass through any mesh section tumbles out the discharge end of the drum. This oversize fraction includes rocks, sticks, roots, debris, and any contamination. It stockpiles separately for disposal, re-grinding, or re-crushing.

The result: one load of mixed material becomes two or three clean, separated stockpiles without a single hand sort.

What Can a Trommel Screen Separate?

Trommels handle almost any bulk material that needs sizing. The mesh panels determine what passes through and what stays in the drum. Swap the panels and the same machine adapts to a different application.

Screen Panel Sizes and What They Produce

The mesh panel size is the single biggest variable in trommel operation. Change the panels and you change the product. Most trommel operators carry multiple sets of panels and swap them based on the job.

Mesh swap takes about 30 minutes per panel on most trommel models. Plan for 2 to 3 hours to swap a full drum set. If you run multiple materials in the same week, schedule mesh changes during shift breaks or between material loads.

Trommel vs Vibrating Screen: Which Do You Need?

Two screening technologies compete for the same jobs. The choice depends on your material.

When to pick a trommel:

• Compost, mulch, and topsoil (organic, fibrous, often damp)
• Wet or clay-heavy soil
• C&D waste with mixed debris
• Any application where the feed sticks, clumps, or contains stringy material

When to pick a vibrating screen (shaker):

• Dry crushed stone and aggregate
• Sand classification
• High-volume quarry production on dry, granular feed
• Applications needing 4+ size fractions in a single pass

For most contractors and landscape supply operations, a trommel is the more versatile choice. It handles wet Monday material and dry Friday material without a swap. Vibrating screens are specialists built for dry, granular processing.

Throughput: How Fast Does a Trommel Screen Material?

Throughput depends on four variables: machine size, mesh opening, material type, and moisture content. Smaller mesh openings slow the process because particles need more exposure time to find an opening. Wet material slows throughput because moisture causes fines to stick together and resist passing through the mesh.

These are estimated ranges based on typical field conditions; actual throughput varies by material type, moisture, and screen size. A qualified operator maintaining steady feed and clean mesh will land toward the upper end. Contaminated feed, oversized debris, and poor feed consistency reduce throughput.

Two Trommel Models for Every Job Size

CZ Screen MDS MIDI

The compact trommel. A 4-foot by 7-foot screening drum on a portable, track-mounted chassis. The MDS MIDI fits tight sites and handles moderate volume for compost operations, landscape supply yards, and small to mid-size topsoil screening jobs. It transports on a standard trailer without oversize permits.

The MIDI is the right machine when your daily volume stays under 400 to 500 cubic yards or when site access limits you to a compact footprint. One loader keeps it fed. One operator runs the show.

Screen USA TROM 512

The production trommel, built by our team at Screen USA. A 5-foot by 12-foot drum with three discharge fractions standard (fines, mids, oversize). Track-mounted. Throughput up to 150 cubic yards per hour on standard material.

The TROM 512 is the machine for landscape suppliers running 1,000+ cubic yards per week, recycling operations processing C&D waste, and composting facilities that need production-level output with consistent grading. The larger drum diameter and longer screening length give material more time and tumbling action inside the drum, which improves separation accuracy.

Common Trommel Applications by Industry

When to Pair a Trommel with Other Equipment

A trommel works best alongside other machines when the job involves mixed materials on the same site.

Trommel + crusher (soil recovery before crushing). On demo sites with mixed concrete and dirt, run the raw material through the trommel first. The screen pulls out reusable topsoil and fines before the concrete goes to the crusher. This recovers sellable dirt that would otherwise get buried in the crusher run pile.

For aggregate sizing after crushing, use a vibratory screener. If the project requires graded aggregate from crusher output (#57 stone, #4 stone, or structural fill), the right pairing is a crusher plus a vibratory screener like the CD410. The screener’s vibrating decks separate crusher run into three graded products in one pass. Trommels work on soil, compost, and organic material. Vibratory screeners work on dry, granular aggregate.

Trommel + grinder (compost and mulch operations). A horizontal grinder reduces stumps, brush, and yard waste into raw mulch. A trommel downstream screens that material into graded mulch, removing oversize chunks for re-grinding. This pairing is standard at landscape supply yards and composting facilities.

GCS connects you with multi-machine packages on a single delivery. One mobilization fee. Crusher and screener for on-site aggregate production. Grinder and trommel for mulch and compost operations. Call to discuss what your job needs.

Trommel Maintenance Basics

Trommels are mechanically simple compared to crushers. The primary maintenance items:

Mesh panels. Inspect daily for tears, holes, and wear. A torn panel allows oversize material into the fines product and ruins the gradation. Replace worn panels before they compromise product quality. Carry spare panels on-site if you are running abrasive material.

Drive chain and sprockets. The drum rotates on a chain drive or gear drive. Check chain tension weekly. Lubricate per the manufacturer schedule. Loose chains skip teeth and cause uneven drum rotation.

Drum seals. Rubber or brush seals at the feed and discharge ends prevent material from bypassing the screen. Worn seals let fines escape around the drum instead of passing through the mesh. Inspect monthly.

Bearings. Grease drum support bearings per the daily schedule. Under-greased bearings overheat and fail. Over-greased bearings push grease past the seals and contaminate the product. Follow the manufacturer spec.

Conveyor belts. Check belt tracking daily. A misaligned belt drops material between the frame and the belt, creating a cleanup mess and losing product. Adjust tracking rollers as needed.

Expected wear life on mesh panels: 500 to 2,000 operating hours depending on material abrasiveness. Topsoil and compost are easy on panels. Crushed concrete and rock wear them faster. Budget for panel replacement if you are running abrasive material for extended periods.

Frequently Asked Questions

What is the difference between a trommel and a vibrating screen?

A trommel uses a rotating drum to tumble material across mesh panels. A vibrating screen uses a flat deck that shakes at high frequency to move material across the mesh. Trommels handle wet, sticky, and fibrous material better because the tumbling action self-cleans the mesh and prevents clogging. Vibrating screens process dry, granular material faster because the high-frequency vibration separates particles efficiently. For most contractor and landscape supply applications involving soil, compost, or mixed materials, a trommel is the more versatile choice.

Can you screen wet material in a trommel?

Yes. Trommels are the preferred screening method for wet material. The rotating drum continuously tumbles the material, which prevents the mesh from blinding (clogging) the way flat vibrating screens do in wet conditions. Expect throughput to drop 30 to 50% compared to dry material of the same type, because wet fines clump together and resist passing through the mesh. Coarser mesh settings help maintain throughput on wet feed.

What sizes can a trommel produce?

Trommel screens accept mesh panels from 1/4 inch to 4 inches. The mesh size determines the maximum particle that passes through. A 1/2-inch mesh produces material with particles up to 1/2 inch in diameter. A 3/4-inch mesh produces material up to 3/4 inch. Most trommel operators carry multiple panel sets and swap them based on the job. Common sizes: 3/8 inch for compost, 1/2 inch for topsoil, 3/4 inch for mulch and coarse fill, and 1.5 to 2 inches for overburden removal and rough separation. For aggregate sizing and road base grading, a vibratory screener is the better tool.

How fast does a trommel screen material?

Throughput ranges from 25 cubic yards per hour on fine, wet material with small mesh to 150+ cubic yards per hour on dry, coarse material with larger mesh. The compact CZ Screen MDS MIDI runs 40 to 80 cubic yards per hour on typical topsoil and compost. The production-level Screen USA TROM 512 runs 80 to 150 cubic yards per hour. Material moisture, mesh size, feed consistency, and operator skill all affect the actual rate.

What maintenance does a trommel need?

Daily: inspect mesh panels for tears and holes, grease drum bearings, check conveyor belt tracking. Weekly: check drive chain tension and lubrication, inspect drum seals. Monthly: inspect drum seals for wear, check all bolted connections for looseness from vibration. Replace mesh panels when holes appear or when product starts showing oversize contamination. On a well-maintained machine, mesh panels last 500 to 2,000 operating hours depending on material abrasiveness. The mechanical simplicity of a trommel (a rotating drum on bearings with a chain drive) means less downtime and lower maintenance costs compared to vibrating screens.

Get Connected with a Trommel Screen

GrinderCrusherScreen has connected contractors and material producers with screening equipment since 1973. Whether you need a compact trommel for a topsoil operation or a production unit for a recycling yard, we match you with the right machine.

Call 770-433-2670 or visit the trommel screen rental page to request pricing.

Need a trommel for soil and compost screening, or a vibratory screener for aggregate grading after crushing? We coordinate multi-machine packages on a single delivery.

Looking to buy instead of rent? Browse trommel screens for sale on GrinderCrusherScreen.com.