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Classic quarry machines

Patutahi Quarry Rock Products NZ QM Magazine Featured Image

While a number of well-loved classic quarry machines are stored or displayed around the country, there can’t be many quarries where they are still operated alongside modern equipment. BY ALAN TITCHALL

We are watching a very antiquated dumper drive up the haul road at Patutahi Quarry near Gisborne.

A Komatsu bulldozer, Cat excavator and Aveling-Barford SL dump truck cleaning up loose material before extending the ramp into the pit to get at the next level down. The boulders will be sold for armour rock for river protection and travel as far as Tolaga Bay – an hour away.
A Komatsu bulldozer, Cat excavator and Aveling-Barford SL dump truck cleaning up loose material before extending the ramp into the pit to get at the next level down. The boulders will be sold for armour rock for river protection and travel as far as Tolaga Bay – an hour away.

It’s not the age of the truck that surprises me so much as the speed at which it climbs towards us.

The quarry, owned by Rock Products, produces gabion, chip, road stone and agricultural lime from a very hard lime resource from hilly slopes about 15 minutes drive from Gisborne (we featured this quarry and its unique relationship with a neighbouring vineyard in the April-May 2016 issue).

The old vehicle is one of four Aveling-Barford SL dump trucks made in the early 1970s and is still putting in a good day’s work. Aveling-Barford was a large UK engineering company making road rollers, motor graders, front loaders, site dumpers, dump trucks and articulated dump trucks in Grantham, Lincolnshire. In 1967, the company became part of British Leyland (see note).

“It’s getting harder and harder to find people to drive these things,” says Mike Ross, the operations manager at Rock Products.

“They are all manual and take a bit of driving.”

He could have added that the gearboxes don’t have synchromesh and full ‘power steering’ was another two decades away when this truck was made.

“Getting engine parts is also tricky – those Leyland engines haven’t been made since mid 1970s.”

The two old, British-made warriors work alongside a late model Cat dumper.

“They are very useful on this tight site,” says Mike. “And it’s ironic you see them both working today as the Cat, which does the lion’s share of the work, is sitting in the workshop getting fixed at the moment.”

Post war austerity

Overburden pushed down to be taken away by an Aveling-Barford AG dumper.
Overburden pushed down to be taken away by an Aveling-Barford AG dumper.

The original quarry opened in 1915 as a Public Works Department site to supply ballast to the doomed inland railway to Wairoa. It was abandoned around 1923 and the plant, largely made of wood, was extensively fire damaged shortly afterwards.

Just after the war a Whanganui contractor called Jack Alderston ventured north to Gisborne to buy some gear. Instead he found an old quarry and some machinery and parts of the branch line were still intact. Using a mixture of existing machinery and rail lines and a new crushing plant, he got the operation back on its feet in 1948.

His son Frank Alderton joined the company after finishing school in 1958. When Jack passed away in 1970, Frank took over as managing director and has owned the company since.

He recalls his father initially stripping the steep hill site by hand. The overburden was thrown down hill by the shovel load, where it was removed by an Aveling-Barford AG dumper. Made in 1940, it was based on a Fordson petrol tractor and believed to be the first Aveling-Barford machine in the country. It has long been retired, but Frank keeps it in a shed near the quarry entrance. The photo on page 23 shows Frank sitting in the driver’s seat when he was about eight years old.

The old dumper was loaded by a Trackscavator, the company’s first new machine purchased off Gough Gough & Hamer in 1948.

“Post-war New Zealand was a pretty austere place,” says Mike picking up the story. “Money and the opportunity to buy new or second-hand equipment was in short supply. Army surplus, government sales, and good old Kiwi ‘can do’ supplied the basis of many a business. Rock Products was no exception.”

Initially the company was called The Gisborne Lime Company, Mike adds. This was changed to Rock Products in 1950. It was also the name of a popular American magazine and Jack got permission to use it from the publisher.

“The 1950s saw significant growth in sales at the quarry, and machinery was built or purchased to meet demand,” says Mike.

“Of course, when you are buying there are always salesmen ready to try and sell you equipment and, around this time, a young salesman from the engineering company Booth MacDonald [Boothmac] turned up on site.

“His name was Keith Niederer.”

Keith, aka Mr Quarryman, was later famous for obtaining the first licence to build the revolutionary, Kiwi-invented, Barmac crusher.

“I think Keith enjoyed dealing with Jack, and vice versa. Bargaining was brutal, usually accompanied by a drink or two. And because of Jack’s phobia of banks after the depression, a deal, if struck, was generally paid for in cash, pulled from a nearby suitcase.”

A couple of Eimco model 104 loaders were acquired in 1956 that had been used on the Rimutaka Rail Tunnel project built by Morrison, Knudson & Downer, recalls Mike.

“These were used for a number of years, loading (or more like throwing) rocks at a variety of hapless Aveling-Barford dumpers.”

That same year Jack finished building another crusher for a second product line in the plant that was a copy of a Johnson Slogger crusher manufactured in Invercargill. With modifications it eventually became a single rotor impactor and, incredibly, is still in use today.

“By now the company was operating road trucks as well as dozers, and was also enjoying the benefits of the new-fangled Hough wheel loaders – truly a great step forward,” continues Mike.

During the 1960s Rock Products acquired a number of local allied companies, including a shareholding in an engineering company called Monk Brothers, which at the time was also the agent for Caterpillar and John Deere – a very useful alliance, says Mike.

Mike started with the company in the same year Jack died – 1970.

“I was a bit smaller in those days and so was often called in to be stuffed down dark small holes to dig out jammed line chains, elevators, and blocked crushers. I should have learnt my lesson and stayed away.

“But there’s something about quarry dust and all that noise – I don’t really know what it is.”

The past four decades

Since starting work at Rock Products just over four decades ago, Mike has seen a lot of gear come and go.

“In 1971 the quarry bought our first Caterpillar articulated loader – a 920 model, which was a big improvement on the tail-wagging Hough.”

This loader was called number 49 as it was bought new on Mike Ross’ (operations manager at Rock Products) 49th birthday. The operator is Marilyn who normally drives a dump truck. She turned up with a hired machine and ended up staying on at the quarry.
This loader was called number 49 as it was bought new on Mike Ross’ (operations manager at Rock Products) 49th birthday. The operator is Marilyn who normally drives a dump truck. She turned up with a hired machine and ended up staying on at the quarry.

The 1974/75 year saw the purchase of a couple of new Aveling-Barford SL dump trucks.

Back then trucks weren’t delivered, they were sold from Palmerston North and driven back to Gisborne ‘flat out’ at 28mph, recalls Mike.

“Those two trucks grew to four, and were our main dump trucks until about 2005 when we bought a Caterpillar dump truck.”

The company also purchased an Atlas Copco air-track drilling rig, and contract drilled around the district for a number of years with this rig and a Gardner Denver.

“Bernie McDonald, from TopRock, eventually bought this machine from us, surrounded with rumours that he was starting a drill museum with the money that he got from the sale of his company to Red Bull,” jokes Mike.

Late 1970s also saw the arrival of the Aveling-Barford SY shuttle dumpers, which were ex Kaimai tunnel grout carts, which replaced the older 1950s’ SF Aveling-Barfords.

These are still servicing the old bin set up at Patutahi and are ‘not so’ affectionately known as pie carts, says Mike.

“After a bit of a false start with a second-hand Poclain digger, which leaked more oil than a supertanker split in half, a Komatsu digger was purchased in the early 1980s, effectively signalling the end of the need for large bulldozers in our operation.

“Today we don’t own a dozer.”

In 1991, Monk Brothers built the quarry’s first mobile cone crusher, which is still part of the company’s portable fleet.

Seventy-odd years on, the Rock Products group of companies is still based at the Patutahi Quarry and still operating a mixture of new and old machinery.

“The old crushing plant is largely unchanged since the 1950s and still breaking rocks, and the occasional person’s spirit. Those government surplus parts and railway lines have proved good stuff,” reflects Mike.

“The older machines have even outlived their manufacturers; the only one left is Cat.”

Note: The Aveling-Barford site in Lincolnshire site was bought by Wordsworth Holdings in 1988, which went into administration in 2010. Barfords was then acquired by Invictas Engineering, which sold the ‘supply of parts’ to Shellplant in October last year. In 2006 Singapore-based ST Kinetics bought the rights to the Aveling-Barford RXD series articulated dump trucks, which are now sold under the TRX Build brand.

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