Whitehall Quarry Unveils New Tertiary Plant to Boost Construction Resources

Whitehall Quarry, a historic and significant resource for the construction industry, has opened its new Tertiary Plant. The expansion aims to tackle existing supply challenges and solidify Winstone Aggregate’s position in the Waikato/Bay of Plenty region.

Whitehall Quarry, which originated as a farm quarry in the 1940s, quickly evolved into a key supplier of Greywacke rock aggregates. Its contribution was instrumental in supporting the construction of the nearby Karapiro hydroelectric dam on the Waikato River. In 1987, the site was acquired by Firth, followed by Winstone's ownership in 1998, marking a new era for the quarry's growth.

The Tertiary Plant is a game-changer for Whitehall Quarry. With the existing plant operating at maximum capacity, the expansion provides an opportunity to double the tertiary capacity and meet the increasing demand for high-quality construction materials. This development will enable the production of higher-value concrete, asphalt, and sealing chip products.

One of the key features of the new plant is its enhanced capabilities and streamlined processes. The Tertiary Plant ensures improved safety measures and quality control, surpassing alternative mobile crushing options. Automation plays a crucial role, allowing for better uptime, safer start-ups and shutdowns, and real-time performance monitoring for optimized throughput.

Furthermore, the Tertiary Plant focuses on creating a safer workspace while reducing carbon usage. Direct conveyor product feed replaces existing truck and loader feed, resulting in reduced diesel usage. Chute-fed stock bunkers offer more efficient product segregation, reducing energy usage and maintenance associated with conveyor systems. This improvement also contributes to enhanced safety, with reduced traffic movements and better access to maintenance and product sampling.

The construction of the Tertiary Plant adhered to ambitious time and cost targets, reflecting Whitehall Quarry's commitment to excellence. The project brought together industry-leading partners, including Rocktec for crushing and screening design, supply, and engineering, Brian Perry Civil for civil groundworks, Ramek Consulting, the project manager, Electrico for electrical infrastructure, and CTEK for plant automation.

The construction of the Tertiary Plant adhered to ambitious time and cost targets, reflecting Whitehall Quarry's commitment to excellence. The project brought together industry-leading partners, including Rocktec for crushing and screening design, supply, and engineering, Brian Perry Civil for civil groundworks, Ramek Consulting, the project manager, Electrico for electrical infrastructure, and CTEK for plant automation.

Key components of the Tertiary Plant include the Terex Cedarapids MVP450X and MVP380X Cone Crushers, Rocktec BTM-96R VSI Crusher, Terex ElJay TSV Horizontal Screens, Rocktec Avalanche wash screens, conveyors, and a 7-bay final product pre-cast concrete bunker system.

Whitehall Quarry's investment in the Tertiary Plant signifies a significant step forward in meeting the construction industry's evolving needs. The expanded capacity, improved safety measures, and product quality control will undoubtedly contribute to the region's development and foster innovation within the sector.