Rocktec designed, built, and installed a high-performance tertiary crushing plant for Stevenson Construction Materials at their Drury Quarry site. This advanced system improves final-stage material processing with dry screening, washing, dewatering, and vertical shaft impact (VSI) crushing.
Project Overview: Tertiary Crushing Plant for Stevenson Drury Quarry
- Client: Stevenson Construction Materials
- Location: Drury, New Zealand
- Industry: Quarrying / Aggregates Production
- Scope: Full design and delivery of a tertiary crushing plant with VSI crusher, dry and wet screening, and stockpile management
The Challenge: Build a Final-Stage Processing Plant with Maximum Flexibility
Stevenson needed a tertiary crushing plant capable of efficiently producing both dry PAP and washed aggregates at up to 200 tonnes per hour. The plant also had to incorporate new VSI technology, dust control systems, and effective dewatering while allowing flexible product handling and stockpiling.
Rocktec’s Solution: High-Efficiency Tertiary Crushing and Screening System
To meet these goals, Rocktec delivered a modular system built around robust and accessible components:
- 25T live capacity hopper with Rocktec F250B vibrating feeder
- Rocktec BTM96 VSI crusher with dual 150kW motors and integrated air transfer dust control
- Dry screening unit: Avalanche 6000 x 2400 double deck screen
- Wash stations: 4200 x 1500 and 3600 x 1500 triple deck Avalanche screens with wash systems
- Rocktec 16” screw dewaterer for water recovery and fines management
- Six concrete stockpile bunkers for clean product separation and easy loadout
The VSI crusher was specially designed by Rocktec to use standard OEM rotor and shaft assemblies, making it easy to maintain and service.
Installation and Performance Testing
- Design Phase: Rocktec modelled material flow, dust suppression, and stockpile access throughout the quarry site.
- Fabrication: Major structures, chutes, and screens were pre-built and painted offsite.
- Installation: Equipment was installed with minimal disruption to existing quarry operations.
- Commissioning: The plant achieved full 200 tph performance targets immediately after inspection and first tests.
Results and Benefits
- High-Volume Output: The tertiary crushing plant consistently processes 200 tonnes per hour of graded product.
- Flexible Production: The system switches between dry and washed aggregate outputs quickly.
- Improved Dust Control: VSI air transfer and screen encapsulation significantly reduce dust emissions onsite.
- Water Efficiency: The dewatering screw system reduces water loss and improves fines recovery.
- Low Maintenance: Modular VSI design simplifies repairs and reduces downtime.
Conclusion: A Reliable and Scalable Tertiary Crushing Solution
This tertiary crushing plant highlights Rocktec’s engineering ability to create custom final-stage processing solutions that deliver clean, high-quality aggregates with maximum efficiency. The Drury Quarry system now provides Stevenson Construction Materials with long-term, scalable production capacity.
Want to Learn More?
To explore more about VSI crushers, screening plants, or tertiary crushing plant design, visit the QuarryNZ website.
If you’re considering a tertiary crushing plant installation or upgrade, contact Rocktec today.