Roadstone: Smarter Asphalt Production with Zappshelter

The Company:

Roadstone is Ireland’s leading manufacturer and supplier of construction materials, aggregates and asphalt products. With a commitment to quality and sustainability, they’re always looking for clever operational solutions that improve efficiency and keep costs down.

Zappshelter is proud to be a trusted partner, having supplied industrial shelter solutions to many Roadstone sites across Ireland.

When Roadstone at Castlebar, Mayo, needed a truly reliable and cost-effective way to keep their Reclaimed Asphalt Pavement (RAP) dry, they chose Zappshelter. Our goal was to design and deliver a custom project that solved this critical requirement perfectly.

The Challenge:

Anyone in the asphalt industry knows that water is the enemy of efficiency. When RAP (Reclaimed Asphalt Pavement) gets wet, vast amounts of energy are needed to dry it during production.

Roadstone needed to build large, permanent storage bays for their RAP. RAP is absolutely key to their sustainable asphalt production goals, but its usefulness hinges entirely on keeping it completely dry.

When RAP isn’t protected, it soaks up moisture. This forces Roadstone to dry the material, leading to frustrating operational delays and extra expenses. Plus, it actually restricts how much valuable recycled material they can confidently incorporate into the final asphalt mix.

Ultimately, this doesn’t just burn more fuel and drive up costs; it can bring the whole production process to a crawl. Roadstone needed a smart solution to ensure their operation was running as smoothly and cost-effectively as possible.

The Solution:

Our solution was a 14m x 18m Zappshelter, which we mounted directly onto interlocking concrete blocks. This setup is ideal because the blocks do double duty: they provide a solid foundation for the structure and form the high, durable push walls of the new RAP bays.

To fully protect the material from the worst weather, Roadstone’s Zappshelter also includes a rear partial end-wall, offering extra shielding from the elements, especially driving rain and wind.

We ensured the Zappshelter was fully customised. It fits the site’s layout and meets their specific material handling needs like a glove.

 The Result:

The results are speaking for themselves. With their raw materials consistently protected and dry, Roadstone is already experiencing the great benefits of reduced production costs. They’re seeing positive impacts across several key areas:

• Material Consistency: The Zappshelter dramatically cuts down on moisture contamination. This means the RAP material is consistently dry and ready for action, helping them avoid those expensive production hold-ups.
• Sustainability: With dry RAP, Roadstone can confidently and consistently hit the maximum possible recycled content in their products. This helps them meet their sustainability goals and reduces their reliance on new/virgin aggregates.
• Efficiency: The heavy-duty, block-mounted structure has created an organised, completely weather-proof storage bay. This allows for high-speed material handling and keeps production continuous and reliable at the asphalt plant.

The successful completion of this project is another great step in our long-standing partnership with Roadstone. It proves once again that Zappshelter can deliver tailored, high-impact operational protection across their entire business.

For us, a successful project is never just about the structure; it’s about the partnership. The fantastic feedback we received from the Roadstone team really highlights what we aim for every time: great service, customised solutions, and a professional, safety-focused approach from start to finish.

Looking to protect materials and boost operations?

Give our team of Sheltologists a call today: 0208 0505 121 or hit the button below…