Rocktec worked with Stevenson Construction Materials to design and install a custom-built quarry processing plant at Drury Quarry, located just south of Auckland, New Zealand. This multi-level facility helps produce large volumes of concrete aggregate, sealing chip, and GAP products for infrastructure and roadworks.
Project Overview: Multi-Level Quarry Processing Plant in Drury
- Client: Stevenson Construction Materials
- Location: Drury, New Zealand
- Industry: Quarrying / Aggregates
- Scope: Design and installation of a new quarry processing plant with integrated legacy systems
The Challenge: Combining New Infrastructure with Existing Equipment
Stevenson needed a quarry processing plant that could produce a wide range of aggregate products while incorporating some of their existing systems. At the same time, the new plant had to be built across three levels. The primary section also needed to be enclosed to control dust and noise. Because of these factors, the plant required careful planning and precise design to ensure smooth operation and consistent flow.
Rocktec’s Solution: A Flexible, High-Capacity Quarry Plant
To meet these needs, Rocktec developed a fully integrated quarry processing plant designed for performance and longevity. Major components included:
- A telescopic radial luffing conveyor for flexible product stockpiling
- An apron feeder capable of delivering up to 750 tonnes per hour
- A network of binsets and belt conveyors across all three levels
- An automated fractionation system in the final screening stage
- A fully enclosed primary crushing section to reduce dust and noise
Because the plant was designed to work with existing infrastructure, Rocktec ensured a seamless connection between legacy and new equipment. As a result, Stevenson achieved a major capacity upgrade without disrupting their ongoing operations.
Screening Upgrade: Enhanced Performance with New Equipment
In 2012, Rocktec also upgraded the site by designing and installing a 20’ x 8’ double deck inclined vibrating screen. This replaced an older unit and provided greater screening precision and improved long-term durability.
Implementation Process: From Design to Operation
- Planning: Rocktec worked closely with Stevenson to plan the plant layout, flow paths, and control systems.
- Fabrication: Equipment was manufactured and tested before being transported to the site for installation.
- Installation: Rocktec installed the plant on-site while Stevenson’s existing operations continued with minimal disruption.
Results and Benefits
- Reliable Output: The quarry processing plant consistently delivers high volumes of multiple aggregate grades.
- Efficient Design: A smart, multi-level layout streamlines the flow of materials and maximises site space.
- Advanced Control: Telescopic conveyors make stockpiling more efficient and reduce site congestion.
- Improved Screening: The new Rocktec screen adds better product control and longer wear life.
Conclusion: A Smart Investment in Long-Term Quarry Processing
This quarry processing plant demonstrates Rocktec’s ability to deliver custom-engineered systems that blend performance, integration, and reliability. Today, Stevenson’s Drury Quarry runs a scalable solution designed for New Zealand’s growing infrastructure demands.
Want to Learn More?
To explore innovations in quarry equipment and bulk handling systems, visit Australian Bulk Handling Review.
If you’re planning to expand or modernise your quarry processing plant, contact Rocktec to start your project.