Kayasand News: 6 July 2025
A Hamilton-based firm is rewriting the rules of construction, using quarry byproduct to build a more sustainable future.
Kayasand, a trailblazer in Engineered Sand™ technology, has signed a landmark multi-million dollar deal with global building materials leader Heidelberg Materials to install its state-of-the-art sand plant at the Bass Point Quarry in New South Wales, Australia.
At the core of the deal? Turning crusher dust, a previously underutilized quarry byproduct, into more than 300,000 tonnes of high-quality engineered sand annually, with the potential for more. The move is expected to boost quarry yields, and future-proof sand supplies in a region facing mounting pressure on its natural supply.
“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,” said Kayasand CEO Bram Smith. “The growth in demand is driven by the construction industry’s drive for sustainable, scalable solutions.”
From By-product to Premium construction material
Often treated as a low-value byproduct, crusher dust is set to become the raw material fueling a sustainability revolution in construction. Kayasand’s V7-120 dry processing plant will transform crusher dust into premium sand with consistent particle sizing, ready for use in high-performance concrete.
The automated plant can operate 24/7 using a waterless and dust-free process. This enables maximum utilization of the plant. “We researched sand manufacturing solutions globally and Kayasand was the only one that met our sustainability and performance criteria,” said Heidelberg Materials NSW Supply Chain Manager Scott Whittaker. “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”.
Heidelberg Materials operates one of the largest networks of quarries, concrete plants, and asphalt facilities in Australia. It also holds a critical share in the nation’s cement production, and is a key supplier for large-scale infrastructure projects, such as roads, bridges, and tunnels.
“Our ability to add the V7-120 on to the end of our existing operation makes this an incredibly efficient expansion for us. The opportunity to fully utilize 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.”
A Strategic Shift for Construction
The timing of the deal couldn’t be more critical. Construction companies in Australia and New Zealand are facing dwindling natural sand availability as environmental constraints and tighter consent processes drive demand for alternative sources.
Smith says innovation and new approaches are needed to ensure sustainable alternatives and lower-carbon solutions.
“Sands that are precision engineered for concrete performance are the future,” says Smith. “They give us much better control of the outcome and are more environmentally sustainable than natural sands.”
Kayasand’s new technology is more than a one-off; it signals a broader industry shift. The company plans to roll out at least 10 plants across both countries by 2030 and is already working with Australian firms that ship crusher dust to Waikato for test processing.
“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.” Bram Smith added.
Award-Winning Innovation
Kayasand’s rise hasn’t gone unnoticed. 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% manufactured sand.
The judges lauded the project’s sustainability credentials and technical execution, reinforcing Kayasand’s role as a leader in the future of low-impact construction.
Looking Beyond Concrete
The deal has also opened doors to broader environmental innovation. The ultra-fine filler that is extracted from the basalt crusher dust at Bass Point shows potential for soil regeneration and carbon sequestration, a promising step toward sustainable agriculture and land rehabilitation.
“This isn’t just a construction story, it’s a blueprint for smarter use of every part of the quarry,” said Smith. “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.”
Media contact:
Libby May 021 378 232
About Kayasand
At Kayasand we believe Engineered Sand™ is a commercially viable, economical and sustainable replacement for natural sand in concrete. As specialists in fine aggregate processing, we have designed our plant and equipment to precisely control the shape, grade, contamination and consistency of the sand made; creating the ideal sand for concrete. We help quarries make the most of what they take out of the ground and be part of the solution to the construction industry achieving net-zero carbon emissions by 2050.