Aggregate Industries Improves Asphalt Production With Opus

Aggregate Industries, a member of the Holcim Group, is one of the UK’s leading suppliers of construction materials, providing stone, asphalt, and concrete to industries such as construction, aviation, and road building. With over 60 quarries and 350 locations, the company plays a critical role in major infrastructure projects across the UK. However, a persistent challenge threatened efficiency and profitability—moisture in recycled asphalt planings (RAP).

Storing RAP outdoors left it vulnerable to rain and humidity, increasing its moisture content and causing significant operational setbacks. The excess moisture required additional drying before use, increasing energy consumption, delaying production, and adding unnecessary costs. High moisture levels caused the plant to jam, forcing a rise in burner temperatures just to achieve the correct mix. This inefficiency disrupted production flow and negatively impacted profitability.

Determined to find a solution, Aggregate Industries partnered with McGregor Group to implement Opus storage bays, designed to create a controlled environment that keeps materials dry and production efficient. McGregor Opus was the ideal choice due to its rapid deployment with minimal disruption to operations. Manufactured and installed by McGregor Structures Ltd., Opus ensured both speed and reliability. The structure’s integrated gutter system efficiently directed water runoff, preventing moisture accumulation, while an advanced air ventilation system enhanced airflow to reduce condensation. The storage bays were delivered and fully constructed within twelve days, allowing Aggregate Industries to see immediate benefits.

The results were transformative. By significantly reducing moisture content in the 20mm recycled asphalt, the company minimised the need for pre-heating, leading to substantial energy savings. Lower energy consumption directly translated to reduced costs, improving the overall return on investment. Additionally, the dry storage environment eliminated production delays, allowing smoother operations and more efficient material handling. With improved safety on-site and a seamless production process, Aggregate Industries not only enhanced profitability but also reinforced its commitment to sustainability and operational excellence.