Rocktec partnered with Boral Quarries to deliver a high-performance crushing and screening plant at their Dunnstown site in Victoria, Australia. This large-scale materials handling solution combined mobile primary crushing with advanced secondary and tertiary systems. As a result, it provided greater throughput, improved flexibility, and consistent asphalt-ready output.
Project Overview: High-Capacity Material Handling for Boral Quarries
- Client: Boral Quarries
- Location: Dunnstown, Victoria, Australia
- Industry: Quarrying & Asphalt Aggregates
- Scope: Design and integration of a 420 tph crushing and screening system
- Completion: 2022
The Challenge: Delivering Throughput with Mobility and Blending Precision
Boral needed a quarry crushing plant capable of processing over 400 tonnes per hour. Moreover, the solution had to deliver precise blending for asphalt-grade aggregates while maintaining flexibility for future site changes. Therefore, the plant needed to perform reliably in tough operating conditions without compromising blend accuracy or operational uptime.
Rocktec’s Solution: Customised Crushing and Screening Plant
To meet these requirements, Rocktec developed a fully customised crushing and screening plant that integrated both mobile and fixed components. Consequently, this design allowed efficient material flow, high output, and smooth coordination between plant stages. Key features included:
- A 700 tph mobile primary crushing unit (LT125)
- A 150m mobile overland conveyor linking to the secondary plant
- A secondary crushing system delivering 420 tph
- Rocktec 16’ x 6’ triple-deck inclined screen for accurate material separation
- A fully integrated pugmill and pre-coat system within the tertiary plant
Furthermore, the 400 tph load-out system included blending and pre-coating functionality—perfect for asphalt applications requiring consistent output.
Implementation Process: From Concept to Commissioning
- Engineering & Planning: First, Rocktec worked directly with Boral’s engineers to model site requirements and design a tailored solution.
- Manufacturing: Then, our fabrication team constructed all components using high-strength materials suited for abrasive conditions.
- Installation: After delivery, mobile and fixed systems were integrated onsite, with precise alignment to optimise performance.
- Commissioning: Finally, Rocktec conducted on-site testing to verify throughput, blending accuracy, and reliability across the system.
Results and Benefits
- High Output: The plant now processes 420+ tph consistently, significantly increasing production capacity.
- Improved Flexibility: Thanks to the mobile primary unit and conveyor, the site can adapt quickly to operational changes.
- Asphalt Compliance: The pugmill and pre-coat setup help meet strict specifications for asphalt-grade materials.
- Accurate Screening: The triple-deck screen ensures clean separation and reliable particle size control.
Conclusion: Rocktec’s Crushing Plant Expertise in Action
This Dunnstown project proves how Rocktec’s engineered solutions can deliver large-scale crushing and screening plant systems with precision and flexibility. By combining mobile efficiency, blending accuracy, and high throughput, the plant offers a scalable and future-proof approach to quarry production.
Want to Learn More?
To explore more insights and industry examples, visit the Quarry Magazine website for additional case studies and articles.
If you’re planning a new aggregate processing plant or require a reliable material handling system, contact Rocktec to start your project.