Rocktec designed, built, and installed a custom hi-lab aggregate plant for Stevenson Construction Materials at their greenfield site in Huntly, New Zealand. This modular, skid-mounted plant produces Hi-Lab specification aggregates, as well as concrete-grade material and a scalping product—supporting a wide range of civil construction needs.
Project Overview: Hi-Lab Aggregate Plant in Huntly
- Client: Stevenson Construction Materials
- Location: Huntly, New Zealand
- Industry: Quarrying / Hi-Lab and Concrete Aggregates
- Scope: Full design, build, and installation of a modular hi-lab aggregate plant
The Challenge: Greenfield Plant with Specialised Output Requirements
Stevenson needed a purpose-built hi-lab aggregate plant that could produce multiple high-spec products on a greenfield site. The plant had to include separate processing for concrete-grade aggregates and support both TNZ and PAP production modes. Additionally, it required a flexible modular layout for future expansion and easy maintenance.
Rocktec’s Solution: Modular, High-Performance, and Versatile
Rocktec delivered a modular, skid-mounted plant configured for both Hi-Lab and general aggregate production. Key equipment includes:
- Rocktec BTM96-R VSI Crusher (300kW) for shaping Hi-Lab product
- Metso GP300 Cone Crusher integrated with Rocktec support structures and walkways
- 4 x Rocktec 16’ x 5’ Avalanche Screens for precise classification
- 16 x conveyors for efficient inter-stage material handling
- An additional screening zone for concrete aggregate production
- Optional TNZ or PAP production modes for spec flexibility
The cone and VSI crushers operate in tandem to meet Hi-Lab performance standards. At the same time, a third screen section allows for the production of various concrete aggregates, expanding the plant’s commercial versatility.
Operational Access and Component Standardisation
Rocktec designed the plant with ease-of-maintenance in mind. The Avalanche screens feature roll-away front chutes for faster access during servicing. Moreover, common wear parts are used across multiple units to reduce spare stock requirements and streamline maintenance procedures.
Performance and Delivery Timeline
- Design: Rocktec collaborated with Stevenson to define plant performance goals and tailor the layout for the greenfield site.
- Fabrication: All plant modules were constructed and tested off-site before delivery.
- Installation: The plant was installed, commissioned, and exceeded its 250 tonnes per hour design throughput in initial operation.
Results and Benefits
- Multi-Spec Output: The system produces three Hi-Lab products, one scalping product, and concrete aggregates.
- Modular Flexibility: The skid-mounted layout simplifies transport, installation, and future upgrades.
- Reliable Capacity: Actual output has already surpassed the 250 TPH performance specification.
- Maintenance Efficiency: Shared wear parts and access features reduce service time and spare stock holdings.
Conclusion: A Future-Ready Hi-Lab Aggregate Plant
This hi-lab aggregate plant highlights Rocktec’s strength in delivering tailored greenfield solutions. With its modular design, high-spec output, and accessible build, Stevenson’s Huntly operation is now well positioned to supply quality material for a broad range of projects.
Want to Learn More?
To explore more about hi-lab production or greenfield modular plants, visit Australian Bulk Handling Review.
If you’re developing an aggregate plant or upgrading your site capabilities, contact Rocktec to start your project.