Whitehall Quarry Plant Upgrade

Project Name: Whitehall Quarry – Tertiary Plant Upgrade

Client: Winstone Aggregates

Location: Whitehall, Waikato, New Zealand

Sector: Quarrying / Heavy Industrial Infrastructure

Services Provided:

– Client-side project management

– Project team establishment & leadership

– Procurement & vendor coordination

– Design (process water system)

– Contractor management

– Construction planning & delivery oversight

– Safety in Design facilitation

Challenge / Objective

Winstone Aggregates required a major upgrade of the tertiary plant at Whitehall Quarry to increase production capacity and support long-term growth. The objective was to deliver a fully functioning, high-performance tertiary processing plant within tight timeframes and a strict budget, all while maintaining day-to-day quarry operations.

The works needed alignment between multiple specialist vendors, designers, and contractors—requiring strong project leadership and an organised project structure to ensure smooth delivery.

Our Approach

RAMEK was engaged as the client-side project manager, responsible for leading the project from planning through to commissioning.

As part of our leadership role, RAMEK led the Safety in Design review with all key stakeholders, ensuring the upgraded plant incorporated all required safety functionality, operational safeguards, and access provisions.

Key aspects of our approach included:

Establishing a complete project structure, bringing together consultants, equipment vendors, electrical and mechanical contractors
Developing a clear delivery plan with defined roles, interfaces, and reporting pathways
Facilitating regular coordination between design, procurement, and construction teams
Leading on-site delivery, resolving issues quickly, and keeping the project moving within tight windows
Ensuring health and safety requirements were embedded throughout all workstreams
Managing budget, programme, and scope to keep the project controlled and predictable

RAMEK acted as the client’s representative throughout, providing practical decision-making, hands-on leadership, and strong communication with all stakeholders.

Results / Outcomes

Delivery of a fully operational tertiary plant
Production capacity doubled, significantly improving quarry output
Delivered within tight timelines and budget constraints
Well-coordinated project involving multiple specialist suppliers
Strong safety performance and efficient on-site execution
A future-proofed plant configuration supporting long-term operational growth

Client Testimonial

“I recently had the pleasure of working with Ramek Consulting on the Whitehall Plant Upgrade project. Our team was facing capacity constraints, and we needed someone with the required skills to help us out. Ramek Consulting was able to step in and provide project and contract management support, as well as a capable site engineer to liaise directly with contractors. I was impressed with their process control, technical ability, and especially the ease of day to day interactions. They were able to provide us with the necessary support and expertise to overcome the capacity constraints within our team. Their services were of high quality, and I would definitely recommend them to others who require similar assistance." Engineering Manager, John Tomlinson - Winstone Aggregates

*Video curtesy of Winstone Aggregates.

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