BALLEYE QUARRY

Pioneering Sustainable Quarrying

Collins Earthworks: A Self-sufficient Powerhouse

With an impressive track record of tackling some of the UK's largest and most complex earthmoving projects, Collins Earthworks has solidified its position as a one-stop shop for construction, demolition, and engineering solutions. Over the years, the company has expanded its capabilities, incorporating soil stabilisation, transport, plant sales and even in-house training to ensure seamless project delivery.

“Our growth into these disciplines allows us to offer our clients a complete end-to-end solution,” says Managing Director David Collins. “Adding the training and transport divisions gives us total control over requirements on and off-site, making us more efficient than ever.”

A Game-changing Acquisition

In late 2023, Collins Earthworks took a monumental step toward self-sufficiency by acquiring BallEye Quarry near Cromford in the scenic Derbyshire Peak District. This historic site, once mined for lead, fluorspar, baryte and limestone, had laid dormant since 2014.

“We saw a great opportunity with BallEye Quarry,” says David Collins. “Its location near our Ripley and Kirkby offices makes it ideal for our operations. By owning the quarry, we gain the flexibility to supply high-quality aggregates for our projects and serve external commercial and domestic customers through our transport division.”

Breathing New Life into a Historic Site

Revitalising the quarry was no small feat. Collins Earthworks has brought the site up to modern standards, ensuring it meets current quarrying regulations while prioritising safety and productivity.

Quarry Manager, Roy Bentley explains, “The site is riddled with old workings and faults, so we’re carefully redeveloping it into safer, more manageable benches.” To tackle this challenge, Collins deployed state-of-the-art equipment:

Volvo EC700 Excavators: One excavator handles extraction while the other breaks oversized material with an eight tonne Indeco hammer.

CAT D9T Dozer: Building wider, safer haul roads to access upper benches.

GipoRec P130 Crusher & Lippmann Screener: Processing over 400 tonnes of material per hour, ensuring efficiency at every stage.

Volvo Loaders & ADTs: Streamlining material transport with L260H loaders and high-capacity A45G articulated trucks.

By engineering smarter solutions, Collins has reduced haul distances and optimised production workflows, ensuring BallEye Quarry becomes a hub for high-quality limestone aggregates.

Driving the Future of Sustainable Quarrying

What sets BallEye Quarry apart is Collins Earthworks’ groundbreaking decision to integrate electric trucks into its operations. Moving toward sustainability, the company invested in a fleet of Volvo FMX Electric trucks to transport aggregates.

“Volvo is leading the way in electric truck technology, and this was the perfect opportunity to make a real difference,” David Collins explains.

Each truck, powered by six batteries and three electric motors, delivers the equivalent of a diesel 666hp engine, but with zero emissions and minimal noise. With a gross weight of up to 44 tonnes, these robust vehicles are ideal for quarry operations and can deliver up to half a million tonnes of material to local infrastructure annually.

“SWITCHING TO EV TRUCKS NOT ONLY REDUCES OUR CARBON FOOTPRINT BUT ALSO REDUCES NOISE POLLUTION AND THE OVERALL IMPACT ON THE LOCAL COMMUNITY”

Decarbonisation with Vision

The shift to electric trucks aligns with the government’s PAS 2080 carbon roadmap, which encourages businesses to reduce their operational carbon footprint.

“This isn’t just about compliance,” says Quarry Manager Roy Bentley. “Switching to EV trucks not only reduces our carbon footprint but also reduces noise pollution and the overall impact on the local community. The residents of Bonsall appreciate the quieter and cleaner operations, especially following 10 years of inactivity at the quarry.”

Developing Portable Power

To support its electric fleet, Collins has invested in off-grid rapid-charging, engineered for harsh environments and capable of powering up to eight trucks simultaneously. Trucks will recharge during downtime and overnight, ensuring maximum efficiency.

Understanding that innovation never stands still, Collins Earthworks is already working on portable battery solutions to extend the range of their electric trucks. Director Jack Cave reveals, “We’re developing portable rapid chargers housed in roll-on, roll-off units. This will allow us to increase the trucks’ versatility and ensure they remain productive on longer-distance projects.”

James Cowen, Managing Director at Hartshorne Group, who supplies Collins trucks adds, “Collins Earthworks is setting an industry benchmark with their EV fleet. Their commitment to a cleaner, greener planet is inspiring.”

If you’re interested in exploring how portable EV charging can support a greener future for your business, contact evpower@collinsearthworks.co.uk to learn more.

A Collaborative Approach

Reopening a dormant quarry is a significant challenge, especially when it comes to addressing the concerns of nearby residents. Collins Earthworks took a proactive, transparent approach by holding open days and maintaining ongoing communication with the community.

“We believe in involving residents every step of the way,” David Collins says. “From sharing blasting schedules to inviting residents to open days to see our operations firsthand, building trust and support.”

The reception has been overwhelmingly positive, with residents appreciating the environmental efforts and the revitalisation of the historic site.

Expanding Horizons

BallEye Quarry represents the beginning of Collins Earthworks’ journey into sustainable aggregate production. With early successes already evident, the company sees potential for further growth.

“This acquisition gives us greater control and flexibility,” says David Collins. “We’re proud to lead the way in sustainable quarrying and excited about what’s next.”

From cutting-edge equipment to electric innovation, Collins Earthworks is transforming BallEye Quarry into a beacon of sustainability, efficiency, and progress - an operation truly paving the way to a greener future.