12,000 Hours and Counting: How this One New Zealand Quarry Built a Decade of Uptime
From the Riverbed to the Road: Who is Raukawa Aggregates?
Raukawa Aggregates Limited is a quarry operation based in Palmerston North, owned and operated by Byfords Construction and the Blackley Group. The bulk of their output comes from old alluvial river run material excavated from the Manawatū River corridor — a geologically rich seam of naturally rounded gravel and sand. In addition to virgin river material, the operation also processes waste concrete, transforming demolition rubble into reusable base coarse aggregate. This dual-stream approach supports both sustainability objectives and commercial demand.
With over 200,000 tonnes processed annually, Raukawa Aggregates supplies material to some of New Zealand's most significant infrastructure ventures — and that means their processing equipment cannot afford to let them down.
The Machine at the Centre of It All: The Keestrack R5
For almost a decade, the backbone of Raukawa Aggregates' processing operation has been the Keestrack R5 — a tracked, mobile impact crusher supplied by Equip2 Processing Solutions. The R5 is a heavy-duty, high-capacity machine designed for demanding primary and secondary crushing applications, capable of producing a wide range of product sizes with efficiency and consistency.
Richard Apthorp, General Manager of Byford Construction and Raukawa Aggregates, describes the machine as central to their operation:
The R5's versatility has been a key factor in its sustained use. At Raukawa Aggregates, it is regularly employed to produce a variety of base course grades — both from raw river run material and from crushed concrete. This flexibility means a single machine can serve multiple product lines, reducing capital expenditure and simplifying operations.
Crucially, the machine is mobile — a feature that has extended its usefulness beyond the primary quarry site. Byfords have deployed the R5 at other locations as project needs have demanded, making it a genuinely multi-site asset.
The guys have really enjoyed working with the machine, and we find it quite versatile. But what we have really enjoyed is how reliable it's been. - Richard Apthorp
10 Years, 12,000 Hours — What Does Reliability Actually Look Like?
In a quarry environment, machinery reliability is everything. Unplanned downtime translates directly into lost production, delayed deliveries, and damaged commercial relationships. For Byfords and Raukawa Aggregates suppliers to major infrastructure projects — equipment failure is not simply inconvenient; it can have serious contractual consequences.
This makes their experience with the Keestrack R5 all the more remarkable. Over ten years of active use, the machine has accumulated in excess of 12,000 operating hours with very few mechanical failures. Apthorp is candid about the minor wear and tear the machine has seen over that time:
Wear parts such as blow bars, impact plates, belts, and rubbers are universally acknowledged as consumable items in any crushing application — their replacement is planned maintenance, not unplanned failure. The clutch issue referenced by Apthorp represents the only notable unplanned mechanical event over a decade of operation — an exceptional track record by any industry standard.
For context, industry benchmarks for mobile impact crushers typically expect planned maintenance interventions every 250–500 hours, with major overhauls becoming necessary around the 5,000–8,000 hour mark depending on application intensity. Reaching 12,000 hours with only routine consumable replacement and a single minor mechanical issue is a testament to both the quality of the machine and the care with which it has been operated and maintained.
There's the usual things like belt rubbers and the normal wear parts. We've had a few cracked bits and pieces of steel. I think a minor breakdown with a clutch — but largely it's been very reliable. - Richard Apthorp
On the Job: Major Projects Powered by the R5
The proof of any quarry operation's capability lies in the projects it has served. Raukawa Aggregates' R5-processed material has been used on some of New Zealand's most high-profile roading and infrastructure developments.
Richard Apthorp cites the Te Ahu a Tauranga Manawatu Tararua Highway and Transmission Gully as notable examples — two projects that demanded consistent, specification-grade aggregate delivered reliably and at scale.
Transmission Gully — the 27-kilometre motorway north of Wellington — was one of New Zealand's largest roading projects, completed in 2022 after years of construction. Projects of this scale place enormous demands on material supply chains, requiring aggregate of consistent quality in very large volumes over sustained periods. The fact that the Keestrack R5 underpinned part of that supply without incident speaks to its suitability for exactly this kind of high-stakes application.
The Equip2 Factor: Why Aftercare Makes the Difference
Purchasing capital equipment is a significant investment decision — but for experienced quarry operators, the machine itself is only part of the equation. What happens after the sale matters just as much: parts availability, technical expertise, response times, and the quality of advice you receive when things need attention.
Richard Apthorp is clear that the support provided by Equip2 has been a decisive factor in his operation's satisfaction with the Keestrack R5:
He goes further, framing after-sales support as one of the most important considerations when evaluating a major equipment purchase:
This is a perspective shared by many of the most experienced operators in the industry. An impact crusher that performs well but is backed by slow parts supply or poor technical support can quickly become a liability. Conversely, a machine supported by a responsive, knowledgeable team retains its value — and its operator's confidence — far longer.
For Byfords and Raukawa Aggregates, the relationship with Equip2 has delivered on both fronts. Apthorp summarises the trust that has built up over a decade of working together.
The Bottom Line
Raukawa Aggregates' experience with the Keestrack R5 and Equip2 is a case study in what long-term value looks like in the quarrying industry. It is not simply about the lowest purchase price or the most impressive specification sheet — it is about a machine that performs day after day, year after year, across demanding real-world applications; and a supplier relationship built on honest advice, timely support, and follow-through.
For operations evaluating mobile impact crushing solutions for aggregate production, recycled concrete processing, or large-scale infrastructure supply, the evidence from Raukawa Aggregates is compelling: 200,000 tonnes per year, 12,000 hours, ten years, two major infrastructure projects — another successful partnership.
One of the great things about owning a Keestrack machine is the service. Equip2 offer a really great service. Certainly can't complain about the service of the machine — the support, the supply. It's really good. - Richard Apthorp
