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Globe-Trotting Concrete Plant Installed At Granite Products

A new concrete plant has successfully been installed at Granite Products

Having completed the long journey from its place of manufacture, a new, state-of-the-art concrete plant has successfully been installed at the Granite Products quarry on the island of Jersey thanks to careful planning, meticulous project management and strong commitment from the many individuals and companies involved in its delivery and installation.

Under the watchful eye of Project Manager, Ian Jordan, preparation of the site, piling and civils began in June 2017, in readiness for the arrival of the plant in October. 

The component parts of the new plant had to be transported in 15 articulated lorries from manufacturer, Meka in Turkey across Europe to the UK, then by sea to Jersey. Once on the island, special permission had to be obtained to move the plant from the docks to the St Peter’s Valley quarry site.  Vehicle movements could only be carried out at night under police escort through the narrow island roads which were closed to other traffic.

“The complex logistics of getting the plant to our site were organised well in advance by our Workshop Manager, Tom Baudains,” explains Simon Clowes, General Manager of Granite Products. “He liaised closely with the DVS and local authority and his local knowledge and expertise were invaluable.”

Once on site, the assembly and installation of the plant required close collaboration between members of the Granite Products team and technicians from supplier Berkshire Engineering Supplies Ltd (BES) and local power company, Jersey Electricity. Laboratory Technician, Graham Holland worked closely with Ian Jordan on the design of the lab and batching area, Electrician, Scott Brennan, took the lead on the electrical installation and Chris Pike, Head of Health and Safety for the Brett Group and the local Health and Safety Committee ensured the safety of everyone involved, in both the installation and future use of the plant, was paramount.

The new fully-computerised plant comprises a main loading tower, with a 2m3 planetary mixer, two loading heads and a half wet facility, and a secondary loading head with a 0.5m3 mixer supplying wet mixed concrete for the collect market.  Aggregate is held in eight hoppers – four 50t covered hoppers feed the main tower directly via a weigh belt, while a further four 25t hoppers can feed either the main or secondary tower via a reversible weigh belt.

These hoppers are supplied by a 55m-long aggregate pre-feeding conveyor and shuttle conveyor with a loading hopper down on the quarry floor. “Taking aggregate from its source in this way reduces the need for loading shovel transport and consequently reduces fuel usage,” explains Mike Cowan, Site Manager at Granite Products.

“The design of the new plant with its three separate covered loading facilities, enables faster turnaround, which we have maximised with improvements in vehicle management on the site,” continues Mike. “The new facility also provides significant environmental benefits over the old plant, with improved energy efficiency, the use of recycled water in the process and a reduction in the amount of cement used.”

The new concrete plant will be commissioned at the end of January 2018 and plans are in place to dismantle and recycle the old plant within six months.  Removing the old equipment will provide access to around six years’ mineral reserve which sits beneath it.  

“This significant investment secures a bright future for Granite Products on Jersey and allows us to provide an even better service to our valued customers on the island,” says Simon Clowes. “Bringing such a complex project to a successful conclusion on time and within budget is a remarkable achievement for the Granite Products team working in collaboration with our suppliers, all of whom have shown enormous commitment and a great range of skills and expertise in getting the job done.”