Rocktec partnered with Stevenson Construction Materials to design and build a high-performance sealing chip plant at Drury Quarry, just south of Auckland. Built on the footprint of the old block plant, this modular system now delivers multiple chip grades and a PAP product for New Zealand’s road construction industry.
Project Overview: Sealing Chip Plant with Modular Design
- Client: Stevenson Construction Materials
- Location: Drury, New Zealand
- Industry: Quarrying / Roading Aggregates
- Scope: Design and build of a modular sealing chip plant with PAP and TNZ-compliant output
The Challenge: Upgrading Output While Reusing Legacy Infrastructure
Stevenson needed a modern sealing chip plant that could reliably produce multiple chip sizes and a PAP product. However, they also wanted to reuse the existing block plant location and infrastructure where possible. Additionally, the system had to be easy to maintain, while offering efficient material flow and consistent product quality.
Rocktec’s Solution: Modular, Accessible, and Efficient
To meet these requirements, Rocktec designed a skid-mounted, modular plant with accessible service points and high-capacity screening. The plant includes:
- A refurbished feed hopper with a new Rocktec vibrating feeder
- A BTM96-R VSI Crusher powered by a 520kW motor
- Two Rocktec 16’ x 5’ Avalanche Screens for primary product separation
- A TEREX 20’ x 8’ Cedarapids Horizontal Triple Deck Screen for high-volume final grading
- 12 conveyors to move material across processing stages
- Optional TNZ production mode for compliance-based output
All crushed aggregate is washed and screened to meet strict size tolerances. As a result, the plant produces five different sealing chip grades and one PAP product.
Designed for Easy Maintenance
Rocktec used common wear parts throughout the plant to simplify spare part inventory. Moreover, the screens include roll-away front chutes, allowing quicker access during servicing and cleaning. These features help reduce maintenance downtime and keep production running smoothly.
Implementation Process: Fast Turnaround and High Performance
- Design: Rocktec collaborated with Stevenson to define performance goals and reuse opportunities within the site.
- Fabrication: Equipment was built, assembled, and tested off-site for quality and fit.
- Installation: The plant was delivered, installed, and brought online with minimal disruption to quarry operations.
Results and Benefits
- Multi-Product Output: The system delivers five chip sizes and one PAP product to meet a range of roading specs.
- Modular Efficiency: The layout supports future upgrades and faster onsite setup.
- High Throughput: VSI crushing and triple-deck screening maximise production capacity.
- Low Downtime: Accessible chutes and shared wear parts reduce service interruptions.
Conclusion: Roading Aggregate, Done Right
This sealing chip plant is a strong example of Rocktec’s modular approach to roading aggregate systems. Designed for output, access, and adaptability, the Drury plant now positions Stevenson to meet market demand with speed and consistency.
Want to Learn More?
To explore sealing chip production or modular aggregate solutions, visit the Australian Bulk Handling Review.
If you’re planning a sealing chip plant or upgrading your existing system, contact Rocktec today to get started.