Size a quarry screen from the feed top size outward: scalp on the top deck, progress the cuts deck-by-deck at roughly a 2:1 ratio, set each wire at 40–60% of its aperture, and run the abrasive decks on Spring steel with matched C/U hooks. That sequence prevents overloading one deck and maximises panel life.
Start from feed top size, not product size. Top deck scalps at ~1.5–2× the top product; each lower deck steps down ~2:1. Size every wire at 40–60% of aperture; heavier wire on top where impact is worst. Use Spring steel across the abrasive decks and match the C/U hook angle to the deck model. Full grade and crimp data is on the crimped wire mesh specifications page.
The feed, not the product, sets the first deck.
The first number in any quarry layout is the feed top size — the largest particle entering the screen. The top deck exists to scalp that oversize, so its aperture is set by the feed, not by the finest product cut. A common rule is to set the top aperture around 1.5–2× the desired top product size, which removes oversize without dumping the whole feed onto one deck.
Zhaobang supplies crimped wire mesh apertures from 3.0 mm to 200 mm and wire diameters 2.0–14 mm, with panels up to 2500 mm wide cut to deck length. That range covers everything from a fine bottom deck to a heavy top deck on a primary quarry screen.
Typical quarry screen mesh runs wire 2.0–6.0 mm with apertures 4–50 mm; a 2.0 mm wire at 5 mesh (5.08 mm aperture) is a standard aggregate cut, and heavy top decks use 8–12 mm wire at a 25 mm aperture.
A roughly 2:1 step keeps every deck loaded near capacity.
| Deck | Function | Aperture | Wire (40–60%) | Crimp / note |
|---|---|---|---|---|
| Top | Scalp oversize | 25 mm | 10 – 12 mm | Lock crimp, heaviest impact |
| Middle | Coarse separation | 12 mm | 5 – 7 mm | Flat top or lock crimp |
| Bottom | Fines cut | 5 – 6 mm | 2 – 3.6 mm | Flat top, smooth flow |
Example 3-deck layout for an aggregate plant; ratios are a starting point, not a fixed law. The bottom deck often carries a 2.0 mm wire at 5 mesh (5.08 mm) as the common aggregate cut.
Heavier wire up top, spring steel across the abrasive decks.
For every deck, keep the wire at 40–60% of the aperture: 10–12 mm wire on a 25 mm top deck, 5–7 mm on a 12 mm middle deck, 2–3.6 mm on a 5–6 mm bottom deck. The top and middle decks see the worst impact and abrasion, so they earn the heavier wire within that band.
Grade follows the same logic. Quarry feed is abrasive, so run the decks on Spring steel, which reaches at least 885 MPa tensile after quench and temper — well above the roughly 600 MPa of 45#. The grade upgrade pays back through fewer changeouts, which matters most on the heavy top and middle decks. Reserve stainless 304/316 for decks that are wet or corrosive rather than simply abrasive.
Open area still matters: thicker top-deck wire lowers throughput, so confirm the deck is not starved. The open-area formula (aperture ÷ (aperture + wire))² × 100 keeps the trade-off visible — see the aperture and wire diameter guide for the worked method.
The heavy decks want the deeper grip.
Heavier top and middle panels on high-tension decks benefit from the deeper-grip U-hook (60°–180° bend), which resists pull-out under high vibration loads. Lighter bottom-deck fines panels can use the shallow C-hook (30°–180°). In every case the hook angle must match the screen brand and deck model, so supply those details with the panel dimensions when ordering.
Tensioning discipline closes the loop: an under-tensioned deck flaps and fatigues the hooks, an over-tensioned deck over-stresses them. Confirm correct tension at installation so the panel reaches its wear-life potential rather than failing early at the edge.
The full hook and crimp reference, including plain, bent and shroud edges, is on the crimped wire mesh specifications page and the crimped wire mesh product page.
The top deck scalps the feed, so its aperture is set by the feed top size, not the product cut. A common rule is to set the top aperture around 1.5 to 2 times the desired top product size so oversize is removed without overloading the deck. It carries the heaviest wire (8–12 mm for a 25 mm aperture) and the spring steel grade because impact and abrasion are greatest at the top.
A workable starting ratio is roughly 2:1 between successive deck cuts (for example 25 mm top, 12 mm middle, 5–6 mm bottom). This keeps each deck loaded near its capacity and avoids dumping too much material onto one screen. Adjust the ratio toward the product specification rather than a fixed rule when a tight gradation is required.
Quarry feed is abrasive and impact-loaded, so panels retire from wear-through. Spring steel reaches at least 885 MPa tensile after quench and temper, versus roughly 600 MPa for 45#, which on a vibrating deck means a much longer service life. The grade upgrade pays back through fewer changeouts, which matters most on the heavy top and middle decks.
Not necessarily. Heavier top and middle panels on high-tension decks benefit from the deeper-grip U-hook (60 to 180 degrees), while lighter bottom-deck fines panels can use the shallow C-hook (30 to 180 degrees). In every case the hook angle must match the screen brand and deck model, so supply those details with the panel dimensions.