Holme Hall Quarry, Rotherham UK  25th March 2025

In March 2025 the Association organised a successful site visit to Breedon’s Holme Hall Quarry.  The evening prior to the visit the Association hosted a dinner for the attendees at Hellaby Hall Hotel, providing a valuable opportunity for networking in a relaxed and welcoming setting…. that was very well received by the members.

The following day, members of the MHEA were privileged to be invited on a very worthwhile site visit to Breedon’s Holme Hall Quarry in South Yorkshire, where Quarry Manager, Steven Gagg, very kindly hosted. 

Members were given a tour of the site in Breedon’s 4 x 4 vehicles and minibus, including the primary crushing area and the newly developed viewing platform, where each part of the quarry’s process was expertly explained by Steven and his team.

Holme Hall Quarry

Holme Hall Quarry is owned and operated by the Breedon Group, a leading supplier of construction materials. The area has been mined and restored as it should be and Breedon continue this restoration work today.

At the quarry, Breedon have Tarmac and Marshalls on-site, two internal customers for them and it works very well.

Everything at the quarry is transported via conveyors, eliminating the need for dumpers which makes the operation cost-effective and ensures lower emissions.  The plant was originally established in 2004 and remains largely unchanged albeit with a few upgrades. One of the newer additions is their internal washing plant, which enables Breedon to wash dust for use in concrete production.

Operations began in 1930 under a company called Butlers. In 1979, the Butler family retired and sold the site to Tarmac. Over the years, the site has seen much investment, significantly increasing production in the 1980s, peaking at two million tonnes annually in the early 1990s.  Last year, Holme Hall reached 1.8 million tonnes, but the highest production recorded was 2.2 million tonnes.

2003 saw investment of £7.6 million with a state-of-the-art system, which remains operational today. The rock extracted is processed and transported via a series of conveyors to the secondary processing plant. In January 2013, the site became part of Hope Construction Materials. Although this site is managed separately, Breedon oversee all operations.

The quarry spans approximately 1.5 miles in length and half a mile in width, though it has expanded to nearly two miles today.  It reaches depths of around 25 metres and they have extracted over two million tonnes of magnesium limestone, which is estimated to be 250 million years old.  Currently, Breedon employs 32 people in the quarry, including explosive experts, engineers, lab technicians, quarry operatives, and drivers.

The blasting operations can remove between 20,000 and 60,000 tonnes of rock at a time.

A 50-tonne excavator collects the blasted rock and loads it into the primary crusher, known as the GIPO, which is capable of processing 1,000 tonnes per hour. This rotary crusher has been in place since 2004. It reduces large two-tonne blocks into pieces as small as 150mm. The primary plant operates at around 650 tonnes per hour, though it has the capacity for higher output.

The conveyor belts transport crushed material to the secondary plant with the longest conveyor belt measuring approximately 2.4 km, with a single section stretching 1 km. The crushed rock passes through various screening processes to produce MOT Type 1 aggregate, which is stockpiled for sale. Any unsold material is sent to the secondary crushing plant, where it is further screened into graded sizes. The plant allows Breedon to customise mix designs, including 10mm and 20mm aggregates, improving efficiency in concrete production.

Breedon have invested heavily in the quarry, enhancing safety, efficiency, and sustainability. One significant improvement includes implementing a ‘bucket down’ policy, ensuring that all vehicles and plant equipment come to a complete stop before movement is resumed.

In 2024, the site was awarded the Northern Extension permit by Doncaster Council, were they have begun preparation for this expansion and expect to commence work in May.  Additionally, they have introduced a new washed dust product, mainly used internally for concrete production. Some external customers have also expressed interest and expect full-scale production by July 2025.

For the last 18 months the site also manages an inert landfill site and recycling operations. Their recycling division processes materials and generates revenue while contributing to sustainability efforts.

Restoration efforts are ongoing, with significant tree planting initiatives. Last year, Breedon planted 150,000 trees. The process is complex, requiring careful planning and compliance with regulations. However, their focus remains on ensuring sustainability and environmental responsibility.