Roadstone is the leading manufacturer and supplier of building materials in Ireland. After almost 60 years at the cutting edge of industry in Ireland, Roadstone’s commitment to our core values remains steadfast. Today we are as dedicated as ever to providing a service to our customers that focuses on people, products and progress.
Roadstone today is represented by two Companies, Roadstone Dublin Limited mainly looking after the greater Dublin area and North East region and Roadstone Provinces Limited looking after most of the rest of the ROI. Primary products include Stone & Aggregates, Concrete, Blocks & Mortar, Blacktop & Contracts. It is mirrored by John A. Wood Limited in Cork & Kerry area and by Northstone in the six counties. In addition there are shared responsibilities nationwide for the management of an Architectural Products Division for Roof tiles, Clay Bricks, Finished Block work & Paving.
Roadstone is a subsidiary of CRH plc the international building materials group. In 2007 CRH plc employed 80,000 people in 27 Countries on 3 Continents at 3,000 locations. The Group is in the top 4 in its sector in the World and is listed on the Irish, London and New York stock exchanges.
Currently in its 59th year - 2008, the success of Roadstone has been built upon three vital elements – People, Products, & Progress. Materials & Products are manufactured at plants operating independently assessed assurance schemes to ISI 9002. The Company is a progressive employer and neighbour in its areas of operation. Individual policy statements can be viewed on the site.
The Company is proud of its record in business and continuous development to the construction industry and the contribution it has made towards building Ireland’s infrastructure and the healthy economy we enjoy today.
Roadstone manufactures all its products and materials to a third party registered quality management system to the international standard ISO 9001 and the Company has over time built up an excellent reputation for competitiveness, reliability, quality and service.
The quality management standard ensures that all quality related operations are conducted in a controlled manner with the emphasis on achieving the required standard consistently and working towards continual improvement.
To achieve our goal of continuously improving our products and services and retain our ISO 9001 certification ALL employees and sub-contractors will play their part. The Company will ensure that all employees are fully conversant with these objectives through an ongoing training and education programme.
This means all employees are working consistently to the agreed procedures as set out in our ISO 9001 documentation and constantly looking for and sharing ways of improving what we produce and do. Line management are directly responsible for implementation of our quality management systems.
Ideas are welcome on improving the effectiveness or efficiency of our operations and service. In this way we will ensure that Roadstone remains the number one choice for YOU our Customers.
Our summary objectives are to:-
origins of Roadstone go back to the early 1930’s when two young Dublin brothers
Tom and Donal Roche started a sand and gravel haulage business with a Bedford truck
operating from a small yard at Inchicore in the suburbs of West Dublin. Initially
called Roche Brothers it later became the Castle Sand Company and developed steadily
during the 30’s and 40’s. The brothers launched the Company changing the name to
Roadstone on the Irish Stock Exchange in 1949. They were supported in this venture
by John Wood who had his own sand, gravel and quarrying business in County Cork
which later joined with the Roadstone Company.
The early years were not easy for the fledgling Company. The Irish economy and the
construction industry languished during the 1950’s and although Roadstone continued
to expand the Company did go through difficult times. However during the 60’s Ireland
entered a period of rapid economic growth and it was then that Management acquired
key geographic land acquisitions with sound underlying stone reserves in preparation
for the future. Some of these reserves continue to prosper today.
led the engineering and production side of the Company while Donal had the difficult
task of ensuring finance and administration kept pace with growth as financial institutions
and suppliers showed some concern at the frenetic rate of development. At this time
the Company also cultivated key people who brought new professionalism to planning,
development, investment and people skills.
In parallel to this story, the Irish cement industry, previously a state body was
also developing rapidly. By the end of the 60’s Irish Cement had become the largest
industrial Company quoted on the Irish Stock Exchange with Roadstone the third largest.
In 1970 the two Companies merged to become Cement-Roadstone Holdings now known as
CRH plc. World-wide, CRH plc now employs 80,000 people in 27 Countries on 3 Continents
at 3,000 locations. The Group is in the top 4 in its sector in the World and is
listed on the Irish, London and New York stock exchanges.
Tom Roche enjoyed an active retirement developing the East and West link toll bridges
and setting up National Toll Roads. He was planning other projects up until his
passing in 1999 aged 83. Donal passed away 3 years later in 2002 aged 83 also.
Roadstone has an Environmental Policy statement which has been communicated to all employees and contractors. The Company recognises that the successful implementation of this policy depends on the ongoing commitment of all those working in the organisation.
An environmental management system has been developed for the Company and all employees are familiar with their own location environmental management system.
Environmental management is critical to the future development of Roadstone and this is a Management priority. Company accreditation to the updated standard of ISO 14001 will continue in 2007 and is in the process of completition.
We aim for continuous improvement as regards the following
Pits & Quarries can and are often restored upon depletion and continue life as a
wildlife habitat for nature.
Truck and wheel wash facilities are installed to help keep the local community roads
clean within the areas we operate.
Suitable lands can be restored to be returned to Agricultural and Horticultural
On-going monitoring of dust, noise and blast control are all important elements
of a well managed environmental policy.
Planting of shrubbery and trees protects the boundary and helps screen the location
from external view while also assisting with dust suppression and control.
Internal fencing and tree planting enhances visual appearance and improves safety.
Our Customer service objective is that Roadstone is dedicated to maintaining and developing it’s position as the leading supplier of building materials in Ireland.
This is achieved through the quality of the Products, Materials & Services we produce & deliver, and attaining the highest levels of Customer Satisfaction through our vigilance in implementing a caring customer service philosophy throughout the Group.
Tel: 01 404 1000
Fax: 01 404 1007
Our parent, CRH plc world-wide now employs 80,000 people in 27 Countries on 3 Continents at 3,000 locations.
Irish Cement Limited
Tel: 041 987 6000
Fax: 041 987 6400
Normal Portland Cement
Rapid Hardening Portland Cement
Sulfate – resisting Portland Cement
Other Special Products
John A. Wood Limited
Tel: 021 480 0100
Fax: 021 480 0123
Concrete Products – Aggregates & Stonefill
Bituminous Macadam & Road Surfacing Limestone Products
Northstone (NI) Limited
Dunmurray, Belfast BT 17 9NU
Tel: 028 9061 1122
Fax: 028 9060 1930
Concrete & Concrete Products, Roof Tiles
Stonefill & Aggregates
Bituminous Macadam & Road Surfacing
Ormonde Brick Limited
Tel: 056 444 0350
Fax: 056 444 1314
Clay Brick Manufacturers
Tyrone Brick Limited
48 Coalisland Road
County Tyrone BT71 6LA
Tel: NI 028 8772 3421
Fax: NI 028 8772 7193
Tel: ROI 048 8772 3421
Fax: ROI 048 8772 7193
Clay Brick Manufacturers
Tel: 061 604 600
Fax: 061 604 603
Building Insulation systems for domestic and industrial applications. Packaging products systems ranging from food to consumer goods.
Premier Periclase Limited
Tel: 041 987 0700
Fax: 041 987 0706
Production of Premier LC Sintermagnesia & Premier SKLS Sintermagnesia primarily for the production of refractory linings within the steel industry
Clogrennane Lime Limited
Tel: 059 9131811
Fax: 059 9131607
Specialist chemical lime producer for the industrial, pharmaceutical, environmental, agricultural and construction sectors.
The Roadstone Quarry at Belgard in West Dublin is one of the largest in Europe, producing in excess of 2million tonnes of crushed stone each year. It is a vertically integrated facility producing both primary products and finished materials. The quarry was acquired by the Company in 1968 by the visionary Tom Roche, a founder member of Roadstone, and production began two years later in 1970.
The complex has expanded over time to include production of concrete, blocks, paving and blacktop products. The quarry floor has reached a dept of 45 meters and estimates indicate at least another 50 years of production remain. The entire process is highly automated. Environmental and quality control procedures are operated to the highest standards. Quality management systems are audited to ISO 9002.
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The first stage in the process is the extraction of limestone rock from the quarry face. This is done by first removing the top-soil and blasting the rock face. A number of holes are drilled down into the rock and are packed with explosive charges. These charges are detonated in a sequence along the quarry face, separated by a gap of several milli-seconds. Up to 60,000 tonnes of rock is released during this process.
The loose rock is then collected by a loading shovel which is one of the largest in the country. The shovel picks up 20 tonnes of rock at a time and loads it into dump trucks for transportation to the primary crusher. Each dump trucks carry between uo to 60 tonnes, enough stone to build a typical house.
The dump trucks empty each load into the primary crusher, which uses a gyratory action to break the rock into pieces smaller than 200mm. The surfaces of the crusher are coated with manganese in order to improve the wear resistance for the throughput of up to 800 tonnes of stone per hour. The crushed stone is then carried by conveyor to the secondary building where it is screened and separated into three products; minus 200mm material, 50mm stone and finer "screenings". The 200mm stone is then passed through a further stage of crushing to produce 125mm stone. These products are then stored in stockpiles before being used in the second stage of aggregate production.
All of the storage areas and conveyor systems in the quarry are centrally controlled, allowing free movement of stone to various parts of the quarry. In this way, production can be fine-tuned in order to vary the quantities of aggregates produced to match market demands. The stone required for the second stage of crushing and screening is automatically taken by feeders located underneath each of the stockpiles. It is transported by covered conveyor to the second stage crushers where it is crushed into smaller sized pieces.
After crushing, the aggregates are transferred by conveyor to the storage silos where the stone is screened into eight different sizes. Dust suppression systems including enclosed transport and water sprays using re-cycled water, ensure that dust levels are kept to a minimum. A complex sequence of multiple screens and feedback systems for filling the storage silos, allow the production to be constantly monitored and controlled. The aggregates are also sampled and tested to ensure that they comply with the appropriate specifications. Each of the eight silos has a capacity of 1,500 tonnes. The aggregates in the silos are stored until required by one of the production plants also located in the quarry.
The main structural element in the sub-base of a road is a granular material. Clause 804 of the Department of the Environment Specification Roadworks - "The Green Book", defines the requirements of this material.
The special properties of 804 is that the stone has an appropriate strength. The grading must also fit into a specified grading envelope. The fine aggregate is especially important in that it is clean, that is non plastic and is present in sufficient quantity to ensure that when laid that material will be tightly bound and be capable of being fully compacted.
Coated materials, Asphalt and Macadam are produced at Belgard for a wide range of uses, from macadam driveways and carparks to highly specialised road asphalt surfacing used in major road and motorway construction. Each mix composition uses carefully selected and graded aggregates to ensure the appropriate strength and wear characteristics of the surfacing are achieved.
Coated materials contain aggregates and limestone filler bound together by bitumen. The materials are mixed and stored at the appropriate temperature for coating and laying. Mix recipes are stored in the computerised batching system in the control room. This dispenses the exact quantities of each component for production as required. A conveyor running along the base of the silos transports the aggregates in the correct proportion to a heating drum.
The blended aggregates are heated to temperatures of up to 180 degrees Celsius as they pass through the drum. After heating, the aggregates are rescreened and separated into hot bins, so that the target grading can be achieved using the computer stored recipe. Dust generated by the process is collected by a bag-filtering system and is re-cycled as filler.
At this stage quantities of both the limestone filler and the hot aggregates are dispensed into the pug-mill, where the hot bitumen is added and the components are mixed by paddles, ensuring that each stone is evenly coated and that the filler is evenly dispersed. The finished material is kept in hot-storage silos at the appropriate temperature where it can be loaded into insulated trucks for transportation to the road construction site.On some projects Roadstone lay the finished material to produce the roads and motorways of Ireland.
The concrete plant at Belgard operates a demand driven process, where production is scheduled daily to ensure that customer orders are fulfilled as quickly as possible. The plant uses wet-batch process utilising twin Wingate tilting-drum mixers. The four types of aggregate required for production are transferred from the main storage silos by conveyor and are stored in fifty tonne compartments in a silo along with two grades of sand. In the control room, specific recipes are entered from customer orders received. As each batch of concrete is started, specific weights of aggregates and sand are dispensed from the storage silo and are transferred to one of the twin mixing drums.
Cement, stored in two 50 tonne, and two 300 tonne silos, is also dispensed into the mixer. A full range of concrete admixtures are available to cater for all specification requirements. At this stage, water is added and the mix is constantly monitored to ensure that it exactly matches the customer specification. When the mixing process is complete, trucks parked below the mixers are filled by tilting the mixer drums and opening the chutes underneath. Each batch contains 3.5 cubic metres of concrete and by alternating mixes between the twin drums, two trucks can be fully loaded from start to finish in just seven minutes.
The mortar plant produces trowel ready mortar which is delivered on site for building construction. The delivery is very flexible, allowing individual sites to take different quantities and colours daily as required. The control system for the plant operates in a similar way to the concrete plant, transferring the two sand aggregates to the mixer by conveyor.
The cement is held in fifty and twenty tonne silos located above the mixer, and the control system dispenses the correct amount of cement into the mixing drum for each batch. A retarder is also added to the mix in order to keep the mortar in a workable consistency for up to 72 hours. Water is added in a controlled way to the dry mixture until the correct batch parameters have been reached. The mixed mortar is then filled into a truck waiting below the mixer chute.
The new Rekers concrete block plant at Belgard has an annual capacity of 30million 100mm solid concrete blocks making it one of the biggest such production facilities in the world. The plant uses state of the art process controls to ensure high standards are maintained throughout the production process. The aggregates used for production are carefully selected to ensure consistency of composition of the finished blocks. Cement used in the block making process is brought from the Irish Cements production plant in Platin. The production process is automated using a production control system which despenses the exact quantities of aggregates, cement and water into the mixer. Mixing is carefully controlled to ensure that the correct moisture content is achieved.
The mixed concrete is fed into a feed drawer in the block press where it is filled into mould boxes which define the shape of the finished block. Excess material is removed from the top of the mould and controlled vibration is applied to compact the block to the correct height. After compaction the mould box is lifted and the palettes containing the formed blocks pass along a conveyor where the blocks are cleaned to remove any excess material. The blocks are then stacked in elevators, ready for curing. A finger car picks up 10 palettes of blocks at a time, transferring them to curing chambers where they are kept for up to 24 hours.
After the curing process is complete, the finger car removes the palettes and transfers them to the final stage of production. Samples of the blocks are removed for testing and the blocks are measured to confirm that they are the correct height. The finished blocks are then moved to the stacking area, where the palettes are removed, washed and recycled back into the production process. The blocks are automatically stacked into cubes and are tagged, wrapped and strapped, ready for transfer to the storage yard outside.
The Rekers Concrete paving block plant is a high volume production process currently producing a variety of different paving blocks including both the Cobbleset and Castlestone ranges. The particular manufacturing process used by Roadstone produces a two layered block, consisting of a high strength concrete base and a fine textured topping layer. A single layer block is also manufactured.
The cement used is delivered in bulk tankers from Irish Cement, another major CRH company based at Platin, near Drogheda. The entire mixing process is totally automated and controlled by PLC's to ensure consistency of manufacture and orderly storage and curing of the blocks.
The aggregates for production are delivered by truck into a ground feed hopper from which each material is fed into covered storage bins. A batching system dispenses the exact quantity of each material by measuring the weight of the aggregate with load cells above the conveyor. The blended aggregates are transferred into a holding hopper above the concrete mixer. Cement is fed to the mixer and water is added in a carefully controlled way so that the resulting concrete has the correct moisture content and consistency. Pigment is added to the mix during the mixing process.
At the start of the process, a palette is moved into position in the block press, the mould-box is lowered onto the palette and the feed drawer fills the mould box with mixed concrete. Flat compaction heads are lowered onto the mould and heavy vibration is applied to compact the block to size. The mould is then lifted and the palette containing the wet paving block moves down the production line.
Palettes containing the formed paving blocks are moved to a storage elevator which stores up to 22 palettes at a time. When the storage elevator is full, a finger car automatically lifts the palettes and transfers them to one of the curing chambers. During the following 24 hour period, the heat developed by the hydration of the cement cures the paving blocks. The curing chambers are highly insulated to contain the heat and humidity produced during the curing cycle.
After 24 hours curing, the paving blocks are transferred by the finger car to lowerators where the product is continually inspected and sampled for laboratory testing. Hydraulic grabs lift the blocks from the palette and stack them into cubes which are strapped and wrapped for protection during storage. Each cube is individually tagged with both a tracking code and a product description prior to being moved from the conveyor for storage in the yard. The blocks are kept in storage until the appropriate strengths have developed. Safe handling strength for secondary processing is achieved at 7 days and full strength for release to sale at 28 days.
The concrete flag press produces a variety of paving flags. Rubber mats in the moulds are used to create different textured finishes. The materials required are transferred by feed hoppers and conveyors to enclosed storage bins. The aggregate, sand and cement are batched into two separate concrete mixers - one for the backing layer and one for a colored topping layer. The batches are mixed using precise control over the moisture content of the concrete, and pigment is added to the topping mix as required.
Paving flags are manufactured upside down. In the two position process the mould is first brought to the working station where the facing concrete is deposited into the mould. Vibration takes place to give a uniform thickness of facing mix in the bottom of the mould. The backing concrete is then dispensed into the mould. At this point the mould is moved to the pressing station where heavy vibration and pressure are applied by a 500 tonne press. This gives the flag its density and strength. The flags are lifted by individual vacuum pads and are moved into a vertical stacking position for curing. A washing stage is used for flags with an exposed aggregate finish. The flags are stored in the factory for 24 hours to allow the concrete to cure to handling strength. When the flags have reached handling strength they are removed to the storage yard for a further 28 days curing prior to release for sale.
The concrete roof tile plant uses a highly automated process in order to produce high volumes of various profiles, colours and sizes of roof tiles. The plant uses a computer controlled batching system which allows complete control over the production process. Washed and graded sand is fed into hoppers and is screened before being dispensed in controlled amounts by the weigh hopper, located above the mixer.
At this stage, water, cement and pigment are added to the mixer in pre-determined amounts and in the correct sequence. After mixing, the mortar is transported to the tile press by conveyors. The tile press shapes and compresses the mortar to form the tiles onto palettes. The formed tiles are then transferred to temperature controlled chambers where they are cured overnight.
After curing, the tiles are washed, and are taken from the palette for surface finishing. They are then transported by conveyor to an inspection and quality control area. After inspection, the tiles are strapped, counted and are stored in a slotted conveyor system before being loaded by forklift to trucks for delivery.
Recently the Plant has added two new products to its range, Roadstone Minislate and Gemini TwinTile. The NEW products required an additional dedicated production line with an investment of approximately €1 million .
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