Whitehall Quarry Plant Upgrade

Client: Winstone Aggregates

Sector: Quarrying & Heavy Industrial Infrastructure

Role: Client-Side Project Manager (Ramy) & Project Engineer (Kevin)

Duration: 12 months

Challenge

To increase production capacity and support future operational growth, Winstone Aggregates undertook a major upgrade of the tertiary processing plant at Whitehall Quarry. The project involved replacing and integrating critical plant infrastructure within an active quarry while maintaining ongoing production, coordinating multiple specialist suppliers and contractors, and delivering the works safely within tight programme and budget constraints.

There was also an issue with constraint in electrical power to site which Ramek had to work through the local power supplier Waipa Networks to overcome.

Ramek's Role

• Client-side project management from planning through commissioning

• Establishment of project governance, reporting, and delivery frameworks

• Procurement management and coordination of specialist equipment vendors

• Design management and technical coordination across multiple disciplines

• Construction management and contractor coordination

• Programme, cost, quality, and risk management

• Stakeholder management across client, consultants, suppliers, and contractors

• Facilitation of Safety in Design (SiD) workshops

• Resolution of technical and construction issues throughout delivery

• Oversight of commissioning and project handover

Project Scope

• Tertiary plant infrastructure upgrade

• Process plant equipment procurement and installation

• Mechanical and structural works

• Electrical and control systems integration

• Process water system design and implementation

• Civil enabling works

• Safety in Design review and implementation

• Construction staging within an operational quarry

• Commissioning and operational readiness

Outcomes

• Tertiary plant successfully delivered on programme and within budget

• Production capacity significantly increased to support future demand

• Successful coordination of multiple specialist suppliers, consultants, and contractors

• Safe delivery within a live operational quarry environment with minimal disruption to production

• Improved plant reliability, operational efficiency, and maintainability

• Safety improvements incorporated through comprehensive Safety in Design reviews

• Effective management of project risks, interfaces, and construction sequencing, avoiding delays and cost escalation

• High-quality project delivery supporting Winstone Aggregates' long-term operational objectives

Project Impact

This project delivered a modernised tertiary processing facility that significantly increased production capacity while improving operational reliability and safety. Ramek's leadership from project planning through commissioning ensured the successful coordination of complex design, procurement, and construction activities, enabling the upgrade to be delivered safely, on time, and within budget with minimal disruption to quarry operations. The completed facility provides Winstone Aggregates with a future-ready asset that supports continued operational growth and long-term performance.

Client Testimonial

John Tomlinson - Engineering Manager