Kayasand has struck a major deal to install its state-of-the-art sand plant at the Bass Point Quarry in New South Wales, Australia.
The multi-million dollar deal with Heidelberg Materials Australia will enable the latter to turn a previously underutilised quarry byproduct into more than 300,000 tonnes of high-quality engineered sand.
“We researched sand manufacturing solutions globally and Kayasand was the only one that met our sustainability and performance criteria,” Heidelberg Materials NSW supply chain manager Scott Whittaker said.
“The primary driver for Bass Point Quarry is increasing the volume of crusher dust that we can convert into sand for our concrete business. Kayasand aligns with our sustainability goals by reducing waste and balancing sales volumes to production volumes in a way that also boosts quarry profitability.”
The sand plant from Kayasand will bolster Heidelberg Materials Australia’s capabilites. The Australian subsidiary has one of the largest networks of quarries, concrete plants, and asphalt facilities with a large share in the nation’s cement production.
“Our ability to add the V7-120 on to the end of our existing operation makes this an incredibly efficient expansion for us,” Whittaker said.
“The opportunity to fully utilise our crusher dust production, at the same time as reducing our dependence on natural sand in concrete, fits with our commitment to developing sustainable building materials.
“It aligns with the broader objectives of the company to apply innovative technologies to deliver sustainable construction materials.”
Emerging market
Kayasand chief executive officer Bram Smith said the company expects to see more demand for alternatives to natural sand.
The company has plans to launch at least 10 of its sand plants in Australia and New Zealand by 2030. It is also working with Australian firms that ship crusher dust to Waikato for test processing.
Its product quality has been increasingly recognised. The company was recently Highly Commended at the 2025 NZ Concrete Construction Awards for its pioneering APD factory floor in Wiri, New Zealand’s first commercial concrete floor made with 100 per cent manufactured sand.
“This is state-of-the-art Japanese technology that replaces the need for natural sand in concrete. In time, it will eliminate that need entirely. The growth in demand is driven by the construction industry’s drive for sustainable, scalable solutions,” Smith said.
“Sands that are precision engineered for concrete performance are the future. They give us much better control of the outcome and are more environmentally sustainable than natural sands.
“The proof is in the testing. Companies in Australia are sending us shipping containers of crusher dust for trials through our V7-40 demonstration plant in New Zealand. We engineer sand to meet their exact specifications and ship it back for them to carry out concrete trials.
“This isn’t just a construction story, it’s a blueprint for smarter use of every part of the quarry. We’re exploring ways to turn every gram of material produced in quarries into something valuable, whether that’s for roads, buildings, or even farming.”
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