Inside the Aggstorm 8 at Appleby Quarry

How cutting-edge washing technology is producing cleaner, higher-quality aggregates for concrete production.

Standing nine metres above the ground at Fulton Hogan’s Appleby Quarry, Bert from Equip2 walks us through the impressive Aggstorm 8 wash plant. This modular MWS installation isn’t just about moving rock—it’s about refining it to exacting standards for concrete production, removing impurities that could compromise quality, and streamlining operations with smart design.

From Hopper to Finished Product

The process begins at a large feed hopper, where material—already screened to 0–20 mm—is introduced to the plant. Fed by a 23 m transfer conveyor, the aggregate starts its journey with water injected right at the start to aid washing efficiency. The first stage is a 12×5 linear-action screen, designed to liberate as much sand as possible from the incoming mix. The separated sand and stone then follow different paths for specialized treatment.

The Log Washer Advantage

From the screen, stone enters the dual-shaft log washer—a powerhouse of paddles and spray bars designed to scrub aggregates clean. Its primary mission:

Remove lightweight contaminants such as sticks and twigs, which can cause costly defects in finished concrete.

Scrub the stone to a high standard, ensuring a quality end product.

Operators can adjust water levels in the log washer via simple slot bars, allowing fine control over the removal of lightweights. Maintenance is equally straightforward—swing bolts and rubber-buffered doors make internal access quick and safe.

Screening and Sand Capture

A second 12×5 three-deck screen takes over, splitting material into three aggregate sizes. Each deck has independent water supply valves, giving operators flexibility to target cleaning where it’s needed most. Static spray bars with flexible couplings reduce wear and downtime.

From here, sand-laden water flows into a sump before being pumped to the CSP-12 cyclone plant for further processing.

Precision Sand Dewatering

The CSP-12, rated for up to 120 t/h, separates sand from silt and other ultra-fines. Inside, a polyurethane cyclone creates a vortex, sending silts out through the overflow while clean sand drops onto a dewatering screen.

The target: a sand moisture content of around 9%—dry enough to go directly into a concrete mix without delay. Adjustable water jets allow operators to fine-tune performance for different feed materials.

Designed for Maintenance and Flexibility

One standout feature of the Aggstorm 8 setup is its accessibility. From modular walkways and safety mats to rail-mounted pump skids that slide out for easy servicing, everything is designed with operator safety and maintenance speed in mind.

Even the aggregate conveyors—three in total, each 23 m long—are built for adaptability. Swivel chutes and wear-minimising flaps make it easy to reposition or adjust for future production changes.

Delivering Quality and Efficiency

Every stage of the Aggstorm 8’s process—from feed to finished product—is geared toward efficiency, product quality, and ease of operation. For Fulton Hogan, this means:

• Cleaner, more consistent aggregates

• Reduced contamination in concrete

• Lower maintenance downtime

• Better stockpile management thanks to long conveyors and flexible layouts

Burt sums it up simply: the combination of the Aggstorm 8 and CSP-12 delivers ready-to-use, high-quality sand and aggregate straight from the plant.

Equip2 supplies and supports MWS wash plants like the Aggstorm 8 across New Zealand and Australia.
For more information or to arrange a consultation, contact the Equip2 team.

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